Komatsu WA480-6 (SN from A47001) 4WD Wheeled Loaders with 6D125E-5 engines (USA) Operate and Maintenance manual (CEAM009103)

Illustrated factory Operate and Maintenance manual for Komatsu 4WD Wheeled Loaders Models WA480-6.

This manual will assist you in operating, and maintaining for your 4wd wheeled loader.
You can use a Windows, Mac, or Android device to view this manual. You only need to have a PDF reader installed.

Covered Models (USA):
   WA480-6 (SN: A47001-)

Format: PDF, 426 pages
Language: English
Table of Contents:
   FOREWORD
   SAFETY INFORMATION
   APPROVED AND NON-APPROVED USES
      Approved Functions
      Non-Approved Functions
   VISIBILITY STANDARD
      Visibility in Immediate Area
      12-M Radius Visibility
      Front/Rear, Left/Right Directions of Machine
      Machine Serial Number/Product Identification Number (PIN)
      Engine Serial Number, EPA Regulations
      Position of Service Meter
      Serial Numbers and Dealer Information
   TABLE OF CONTENTS
   SAFETY AND WARNING DECALS
      Location of Safety Decals
      Safety Labels
   GENERAL SAFETY RULES AND PRECAUTIONS
      General Safety Rules
      General Safety at Job Site
      Working on Loose Ground
      Safety Features
      Personal Protective Equipment
      Keep Machine Clean
      Fire and Explosion Prevention
      Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid
      Fire Caused by Accumulation of Flammable Material
      Fire Coming from Electric Wiring
      Fire Coming from Hydraulic Line
      Windshield Washer Fluid
      Action If Fire Occurs
      Fire Extinguisher and First Aid Kit
      Fire Prevention and Suppression
      Fire Prevention Steps
      Fixed Fire Detection System
      Fixed Fire Suppression System
      Fire Prevention Procedures
      Precautions When Cleaning Cab Glass
      Dust Hazards Precautions
      Keep Operator's Cab Clean
      Unauthorized Modifications
      Leaving Operator’s Compartment
      Mounting and Dismounting
      Crush or Pinch Point Dangers
      Inside Operator’s Compartment
      Precautions When Using ROPS
      Emergency Escape From Operator's Cab
   PRECAUTIONS BEFORE STARTING OPERATIONS
      Pre-Operational Checks
      Starting Your Work Operations
      Seat Belt Inspection
      Work Site Hazards
      Avoiding Dangerous Situations
      Working Clearances
      Operating on Snow or Icy Surfaces
      Precautions in Cold Areas
      Asbestos Hazard Alert
   RULES FOR ROAD TRAVEL
      Traveling in Reverse
      Travel on Slopes
      Parking the Machine
   PRECAUTIONS DURING MAINTENANCE OPERATIONS
      Warning Tags
      Equipment Storage
      Working Under the Machine
      Using Drop Lamps
      Keeping the Machine Clean
   HANDLING TIRES
      Precautions When Storing Tires
   PERFORMING GENERAL MAINTENANCE PROCEDURES
      Running the Engine During Maintenance
      Proper Tools
      Engine System High-Voltage
      Welding, Grinding or Cutting
      When Using Hammer
      Refueling the Machine
      Cooling System Precautions
      Battery Precautions
      Starting the Machine
      High-Pressure Hoses
      Safety Handling High-Pressure Hoses
      Precaution For High Fuel Pressure
      High Temperature Areas
      Disposal of Waste Materials
      Inflating Tires
      Accumulator
      Critical Parts
   TRANSPORTING THE MACHINE
      Loading and Unloading a Trailer
      Loading Machine
   TOWING THE MACHINE
   GENERAL VIEW
      General View Of Machine
      General View of Controls and Gauges
      Machine Monitor
      Switch Panel
   EXPLANATION OF COMPONENTS
      Machine Monitor
      Types of Warnings
      Emergency Stop
      Caution
      Mistaken Operation
      Inspection and Maintenance
      Central Warning Lamp
      Character Display Portion
      Service Meter
      Action Code Display
      Failure Code Display
      Filter, Oil Replacement Time Display
      Emergency Stop Items
      Brake Oil Pressure Caution Lamp
      Engine Oil Pressure Caution Lamp
      Battery Charge Circuit Caution Lamp
      Steering Oil Pressure Caution Lamp (if equipped)
      Caution Items
   Meter Display Portion
      Torque Converter Oil Temperature Gauge
      Engine Coolant Temperature Gauge
      Hydraulic Temperature Gauge
      Fuel Gauge
      Speedometer
      Meter Display Pilot Lamp
   OTHER FUNCTIONS OF MACHINE MONITOR
      Overall Menu
      Displaying Odometer
      Resetting Filter, Oil Replacement Time
      Entering Telephone Number
      Selecting Language
      Adjusting Monitor Brightness
      Switching Travel Speed/Engine Speed Display
      Switching Travel Speed/Engine Speed Display/Non-Display
   SWITCHES AND CONTROLS
      General View
      Ignition Switch
      Power Mode Selector Switch
      Transmission Shift Mode Selector Switch
      Transmission Cutoff Switch
      Transmission Cutoff Set Switch
      Lamp Switch
      Turn Signal Lever
      Dimmer Switch
      Horn Button
      Hazard Lamp Switch
      Parking Brake Switch
      Front Working Lamp Switch
      Rear Working Lamp Switch
      Machine Monitor Mode Selector Switch 1
      Machine Monitor Mode Selector Switch 2
      Kickdown Switch
      Hold Switch
      Front Wiper Switch
      Rear Wiper Switch
      Cigarette Lighter
      Room Lamp Switch
      Rear Heated Wire Glass Switch
      ECSS Switch
      Emergency Steering Switch (if equipped)
      Cooling Fan Reverse Rotation Switch (If Equipped)
      Cooling Fan Auto-Reverse Rotation Switch (If Equipped)
      Conditions for Switching Fan Rotation
      Torque Converter Lockup Switch (if equipped)
   CONTROL LEVERS, PEDALS
      General View
      Gearshift Lever
      Manual Shift
      Automatic Shift
      Directional Lever
      Gearshift Lever Stopper
      Work Equipment Lock Lever
      Bucket Control Lever
      Lift Arm Control Lever
      Brake Pedals
      Accelerator Pedal
   SECURITY LOCKS AND SAFETY FEATURES
      Steering Tilt Lock Lever
      Frame Lock Bar
      Cap with Lock
      Fuel Tank Filler Port Cap
      Back-Up Alarm
   MACHINE FEATURES
      Towing Pin
      Grease Pump
      Cab Door
      Emergency Escape Right Door
      Left Cab Door, Door Open Lock
      Left Cab Door, Knob
      Left Cab Door, Handle
      Left Cab Sliding Window (Lock Release Knob)
      Cab Wiper
   ELECTRICAL
      Power Outlet
      Fuses
      Fuse Capacity and Name of Circuit
      Slow-Blow Fuse
   WORK OPERATIONS
      Walk-Around Check
      Precautions Before Starting Work Operations
      Check Before Starting Engine
      Check Machine Monitor
      Check Coolant Level, Add Coolant
      Check Oil Level in Engine Oil Pan, Add Oil
      Check Water Separator, Drain Water
      Check Air Cleaner
      Electric Air Cleaner Clogging Sensor
      Check Fuel Level, Add Fuel
      Check Electric Wiring
      Check Inflation Pressure of Tires
      Check Condition of Window Washer Spray
      Check Wiping Efficiency of Wiper
      Check Horn
      Check Defroster Function
      Check Locks
      Check Emergency Exit
      Adjustments
      Adjusting Seat
      Removing or Installing Headrest
      Adjusting Seat Belt
      Adjusting Lever Stand
      Adjusting Mirrors
      Final Checks Before Starting Engine
      Starting Engine
      Normal Starting
      Starting in Cold Weather
      Automatic Warming-Up Operation
      Operations and Checks After Starting Engine
      Checks After Starting Engine
      Breaking in the Machine
      Normal Operation
      Stopping Engine
      Check After Stopping Engine
      Moving the Machine (Directional, Speed), Stopping the Machine
      Moving the Machine
      Changing Gear Speed
      Changing Direction
      Automatic Shift
      Stopping the Machine
      Transmission Cut-Off Function
      Adjusting Transmission Cut-Off Position
      Canceling Transmission Cut-Off Position
      Stopping When Transmission Cut-Off Is On
      Turning
      Emergency Steering (if equipped)
      Emergency Steering Self-Check Function
      Operation of Work Equipment
      Work Equipment Lock Lever
      Lift Arm Control lever
      Bucket Control Lever
      Work Possible Using Wheel Loader
      Digging Operations
   HANDLING TIRES
      Precautions When Handling Tires
      Tire Pressure
   TRANSPORTATION
      Transportation Procedure
      Loading and Unloading Trailers
      Loading Machine
      Securing Machine
      Unloading Machine
   LIFTING MACHINE
      Lifting Position
      Lifting Procedure
   COLD WEATHER OPERATION
      Precautions for Low Temperature
      Fuel and Lubricants
      Coolant
      Battery
      Precautions After Completion of Work
      After Cold Weather
   LONG-TERM STORAGE
      Before Storage
      During Storage
      After Storage
   AUTOMATIC AIR CONDITIONER
      Control Panel
      Main Power Switch
      Fan Switch
      Air Conditioner Switch
      Auto Switch
      Temperature Switch
      FRESH/RECIRC Selector Switch
      Mode Selector Switch
      Method of Operation
      Cooling Operation
      Heating Operation
      Drying-Heating and Demisting Operation
      When Not Using the Air Conditioner Regularly
      Precautions When Using Air Conditioner
      Inspection and Maintenance
      Cool Box
   KOMTRAX
      Basic Precautions
   TROUBLESHOOTING
      When Machine Runs Out of Fuel
      Towing the Machine
      When Engine Can Be Used
      When Engine Cannot Be Used
      Releasing Parking Brake
      Emergency Travel Operation
      If Battery is Discharged
      Precautions
      Removal and Installation of Battery
      Precautions for Charging Battery
      Starting Engine With Booster Cables
      Precautions When Connecting or Disconnecting Booster Cable
      Connecting Booster Cable
      Starting Engine
      Disconnecting Booster Cable
      Lowering Work Equipment When Engine Has Stopped
      Other Troubleshooting
      Electrical System
      Chassis
      Engine
   GUIDES TO MAINTENANCE
      Check Service Meter
      Komatsu Genuine Replacement Parts
      Komatsu Genuine Oils
      Always Use Clean Washer Fluid
      Always Use Clean Oil And Grease
      Checking For Foreign Materials In Drained Oil And On Filters
      Fuel Strainer
      Welding Instructions
      Do Not Drop Things Inside Machine
      Dusty Work Sites
      Avoid Mixing Oil
      Locking Inspection Covers
      Bleeding Air From Hydraulic Circuit
      Precautions When Installing Hydraulic Hoses
      Checks After Inspection and Maintenance
   OUTLINES OF SERVICE
      Handling Oil, Fuel, Coolant, And Performing Oil Clinic
   WEAR PARTS
      Wear Parts List
   RECOMMENDED FUEL, COOLANT, AND LUBRICANT
      Fuel, Coolant, and Lubricant Ambient Temperature Chart
      Recommended Brands, Other Than Komatsu Genuine Oil
      Biodiesel Usage
      Biodiesel Recommendation for Komatsu Engines
      Biodiesel Terminology
      Certification and Standards
      Warranty and Use of Biodiesel Fuel in Komatsu Engines
      Requirements for Using Biodiesel Fuel in Komatsu Engines
      Properties of Biodiesel
      Komatsu Biodiesel Blend Specification for B5 to B20
      Summary of Recommendations
   STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
      Torque List
   PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
      Safety Critical Parts List
   MAINTENANCE SCHEDULE CHART
   SERVICE PROCEDURE
      Initial 250 Hours Service
      Initial 1000 Hours Service
      When Required
   Every 50 Hours Service
      Drain Water, Sediment from Fuel Tank
   Every 100 Hours Service
      Lubricate Rear Axle Pivot Pin
      Check Oil Level in Hydraulic Tank, Add Oil
   Every 250 Hours Service
      Check Battery Electrolyte Level
      Check Parking Brake
      Check Alternator Belt Tension, Adjust
      Check Air Conditioner Compressor Belt Tension, Adjust
      Check for Loose Wheel Hub Nuts, Tighten
      Clean Element in Air Conditioner Recirculation Filter
      Check Function of Brake Accumulator
      Lubricating
   Every 500 Hours Service
      Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
      Replace Fuel Prefilter Cartridge
   Every 1000 Hours Service
      Replace Fuel Main Filter Cartridge
      Change Oil in Transmission Case, Replace Oil Filter Cartridge, Clean Strainer
      Clean Transmission Case Breather
      Lubricating
      Replace Corrosion Resistor Cartridge
      Check Engine Air Intake Piping Clamps for Looseness
   Every 2000 Hours Service
      Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element
      Replace Hydraulic Tank Breather Element
      Change Axle Oil
      Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter
      Check Brake Disc Wear
      Check Function of PPC Accumulator
      Check Alternator
      Check Engine Valve Clearance, Adjust
      Check Starting Motor
      Check Vibration Damper
   Every 4000 Hours Service
      Lubricating
      Check Water Pump
      Check Air Conditioner Compressor, Adjust
      Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber
      Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber
   Every 8000 Hours Service
      Replace High-Pressure Piping Clamps
      Replace Fuel Spray Prevention Cap
   SPECIFICATIONS
   JOYSTICK STEERING SYSTEM
      Structure and Function
      Components
      Shift UP, Shift DOWN Switches
      Directional Selector Switch
      Joystick Steering Lever
      Joystick ON/OFF Switch
      HI/LOW Selector Switch
      Horn Switch
      Console Tilt Lever
      Console Fore-and-Aft Adjustment Lever
      Joystick Pilot Lamp
      Armrest Adjustment Lever
      Steering with Joystick Lever or Steering Wheel
      Precautions for Steering with Joystick
      Operating the Joystick Steering System
      Getting In and Out of Operator’s Cab
      Adjustments
      Adjusting Joystick Console
      Adjusting Seat
   LOAD METER
      Outline of Load Meter
      Principle of Load Meter Measurement
      Conditions for Starting Measurement
      Conditions for Completing Measurement
      Conditions for Successful Measurement
      Method of Calculation and Display
      Points to Remember to Ensure High Accuracy
      Calibration
      When Measuring
      Using Load Meter
      Setting Addition Mode
      Setting Subtraction Mode
      Total Load Data Display
      Clearing Total Load
      Stopping Load Meter Calculation
      Selecting Load Material Category Display
      Calibrating With Empty Bucket
      Calibrating with 1/2 Rated Load
      Calibrating With Rated Load
      Resetting Calibration
      Method of Using Addition Mode
      Method of Using Subtraction Mode
      Printout from Load Meter
      Selection of Printout Mode
   TORQUE CONVERTER LOCK-UP
      Components
      Torque Converter Lock-Up Switch
      Torque Converter Lock-Up Pilot Lamp
      Shift Indicator
      Character Display
      Method of Operation
      Warning/Limit Functions for Travel Speed
      Travel Speed Warning Function
      Travel Speed Limit Function
   AM/FM RADIO CASSETTE STEREO SOUND SYSTEM
      Sound System Components
      Power Switch/Volume
      Auto-Store/Preset Scan Button
      Bass Control Knob
      Treble Control Knob
      Loudness Button
      Time/Radio Display Selector Button
      Tape Eject Button
      Cassette Door
      Fast-Forward, Rewind Buttons
      Preset Buttons
      Metal Tape Button
      Manual Tuning Buttons
      Seek Tuning Buttons
      Band Selector Button
      Method of Operation
      Setting Preset Buttons
      Using Auto-Preset
      Using Manual Preset
      Listening to Radio
      Listening to Cassette Tape
      Reversing the Tape
      Precautions When Using
      Handling Cassette Tape
   MULTI-FUNCTION LEVER
      Components
      Work Equipment Lever
      Kickdown Switch
      Hold Switch
      FNR Switch
      Directional Selector Switch Actuation Switch
      Directional Selector Pilot Lamp
      Work Equipment Lock Switch
      Using FNR Switch to Change Between Forward and Reverse
   BUCKET AND TIRES