Komatsu WA480-8 Manual

Operation & Maintenance
Manual
VENAM51500
WA480 -8
WHEEL LOADER
SERIAL NUMBERS H53051 AND UP
1000010 AND UP
Incorrect operation and maintenance of this machine
may be hazardous and cause injuries. The operator and
maintenance personnel must read this manual before
commencing operation or maintenance. Keep this
manual within reach at all times and ensure that
operating personnel read it at regular intervals.
DANGER
© 2018 KOMATSU
All Rights Reserved
Printed in Europe 07-2018
ORIGINAL INSTRUCTIONS

.

FOREWORD
Komatsu recommends that any service parts used for maintenance, repair or
replacement of emission control systems be genuine new Komatsu or Ko-
matsu approved rebuilt parts or assemblies or others parts of equivalent
quality, and that the engine be serviced by an authorized Komatsu distribu-
tor. Failure to follow these recommendations could result in ineffective serv-
ice, damage to the product or safety risks (including personal injury or
death).
1-1

READ THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be observed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the in-
dicated location so that all relevant personnel can read it at any
time.
Keep it in the storage door (1) beside the shoes box on the left
side of the operator's seat.
If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult your Komatsu distributor before
operating the machine.
EU DIRECTIVES
Machines supplied by us fulfil the Directive for Machinery 2006/42/EEC and all supplements.
If the machine is being used in another country, it is possible that certain safety regulations and specifications
may not be fulfilled for use in that country. For example, priority vehicle warning lamps may be used in some
countries, but are forbidden in others.
Please contact our dealer before using the machine if you have any questions regarding the fulfilment of stand-
ards and regulations in a specific country.
Notes on subsequent installation of electrical and electronic equipment and components.
READ THIS MANUAL FOREWORD
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Electrical and electronic equipment and/or components which have been installed subsequently, emit electro-
magnetic radiation which can influence the function of the electronic components and sections of the machine.
This can have an influence on the safety of the machine and endanger persons. For this reason, please ensure
that the following safety 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 responsibility that the installations do not cause any dis-
turbance to the vehicle’s electronic system or other components. Above all, you must ensure that any subse-
quently installed electrical and electronic components comply with the EMV Directive 2014/30/EU in its current
edition and bear the CE mark.
The following requirements also have to be met for subsequent installation of mobile communication systems
(e.g. radio, telephone):
• Only equipment approved by national legislation (e.g. BZT approval for Germany) may be used.
• The unit must be fixed in position.
• Portable or mobile units may only be used inside the vehicles if they are connected to a fixed outside anten-
na.
• The transmitter unit must be spatially separated from the vehicle’s electronic system.
• Make sure when installing the antenna that this is installed correctly with good earth connection between
antenna and vehicle mass.
Also observe Komatsu and manufacturer’s installation instructions for wiring, installation and maximum permit-
ted power consumption.
FOREWORD READ THIS MANUAL
1-3

KOMATSU MACHINE OPERATOR PRIVACY POLICY
This Privacy Policy governs the processing of personal data which takes place when operators based in the Eu-
ropean Economic Area or EEA (which consists of the EU, Norway, Liechtenstein or Iceland) operate Komatsu
machines equipped with Machine Monitoring Systems such as KOMTRAX, KOMTRAX Plus, K-plus 2, iMC or
Smart Construction Cloud system (hereinafter together referred to as "Machine Monitoring Systems" or "MMS"),
i.e. systems that allow the wireless monitoring of Komatsu machines.
The MMS are globally managed and maintained by Komatsu Limited, a Japanese corporation having its princi-
pal place of business at no. 3-6, Akasaka 2-Chome, Minato-Ku, Tokyo, Japan ("Komatsu"). MMS are made
available in the EEA by Komatsu Europe International NV, a corporation organised and existing under the laws
of Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels un-
der number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the
EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to
MMS.
1. Who is responsible?
Komatsu, Komatsu Europe, Komatsu distributors and dealers, as well as the owner of the machine and your
employer (when your employer is not the owner) are all responsible for the processing of your personal data
through MMS.
2. How are responsibilities allocated?
To arrange for the aforementioned shared responsibility, Komatsu, Komatsu Europe, the distributors, dealers,
owners and your employer have put in place contractual arrangements between them which govern this shared
responsibility.
The essence of these arrangements is that you can always direct your questions and requests regarding
the processing of your personal data (i.e. storage, collection, transfer etc. of all information that relates to you as
operator) to the party with whom you have most direct relationship.
In principle this means that you should first and foremost refer to your employer (if you are an employee) or
your customer (if you are an independent contractor). Komatsu, Komatsu Europe, Komatsu distributors and
dealers, as well as the owner of the machine and your employer/customer (if he is not the owner) will liaise be-
tween each other to ensure that your questions, requests and rights regarding the processing of your personal
data are given due regard.
To be clear:
• For staff members of Komatsu Europe or of other Komatsu subsidiaries in the EEA, the request can be di-
rected directly to Komatsu Europe by sending an e-mail to [email protected]
• For staff members or independent contractors of a distributor, a dealer or an owner, meaning you either
work for or on behalf of a distributor, a dealer or an owner, you are to contact the distributor, the dealer or
the owner with your questions or requests.
•For staff members or independent contractors of another entity than the ones referred to above, you are to
contact first and foremost your employer or customer.
If you are unsure who to contact, please send an e-mail to Komatsu Europe at PrivacyOf[email protected] stat-
ing your full name, function title and entity you work for, and we will refer your request to the appropriate respon-
sible party.
3. What sort of personal data is processed?
When you use a machine equipped with MMS, the following types of personal data are collected and process-
ed:
• personal identification data (e.g. names)
• current employment (e.g. function title and employer details)
• details regarding:
• your use and operation of the machine
• machine location and position
• usage times and statistics
• error codes and frequency of those codes
KOMATSU MACHINE OPERATOR PRIVACY POLICY FOREWORD
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• pictures, videos and sound recordings
4. Why is your personal data processed?
When you use Komatsu machines equipped with MMS, your personal data are processed for the following rea-
sons:
(a) Safety and security
(b) Warranty
(c) Misuse and theft prevention
(d) To provide training and develop training materials
(e) To improve machine and operational efficiency
(f) To improve jobsite safety and efficiency
(g) To provide faster and more tailored support service
(h) To optimize jobsite layout, machine resource allocation and driving routes
(i) For real-time jobsite monitoring and management
(j) Where applicable: to follow-up on rental agreements
(k) To improve MMS and associated services
(l) To evaluate, analyse and report on machine usage
(m) To comply with a legitimate request from law enforcement or other authorities
We may also process your personal data to inform a third party in the context of a possible merger with, acquisi-
tion from/by or demerger by that third party, even if that third party is located outside of the EU.
Please note that your employer can also use MMS to process data to evaluate your performance as employee
as well as for other purposes, but this is entirely between you and your employer.
5. What makes the processing of your personal data legitimate?
The data protection laws require us to precisely indicate to you which legal option we rely on to make the proc-
essing of your personal data legitimate. We need to clarify this for each of the purposes listed in section 4
above.
For the purposes (a) to (l) as indicated in section 4 above as well as for the purpose of informing a third party in
the context of a possible merger, acquisition or demerger, the processing of your personal data is necessary for
our legitimate interests, which in this case concern:
• ensuring the safe and secure deployment of the machines
• preventing misuse and theft
• commercial interests which include handling warranties, the need to be able to improve MMS, our ma-
chines and services and training materials and the need to be able to enter into corporate transactions.
For purpose (m) we need to process your personal data to comply with our legal obligations.
6. Recipients and transfers
Your personal data may be sent to the following categories of recipients:
• yourself
• your employer or business relations
• companies within the Komatsu group of companies, including our affiliates, as well as our service providers
who help us to provide MMS
• governmental, judicial and other competent bodies in case of a justified yet legally binding request
Your personal data are transferred to Japan, for which model contract clauses on the basis of European Com-
mission decision 2004/915/EC have been put in place between Komatsu and Komatsu Europe.
For more information, please address your questions to [email protected]
7. How long will your personal data be stored?
Your personal data are only processed for as long as needed to achieve the purposes listed in section 4 above.
We will de-identify your personal data when they are no longer necessary for the purposes outlined in the pur-
pose for processing, unless there is:
FOREWORD KOMATSU MACHINE OPERATOR PRIVACY POLICY
1-5

• an overriding interest of Komatsu, Komatsu Europe or any third party in keeping your personal data identifi-
able
•a legal or regulatory obligation or a judicial or administrative order that prevents us from de-identifying them
8. Which rights do you have with regard to the processing of your personal data?
You have the right to request access to all personal data processed in MMS insofar it pertains to you. You can
exercise this right first and foremost via most MMS directly. We reserve the right to refuse multiple requests for
access that are clearly submitted for causing nuisance or harm to Komatsu, Komatsu Europe or other parties.
You have the right to ask that any personal data pertaining to you which are inaccurate, are corrected free of
charge. Some personal data you can correct yourself if you have access to the MMS web portal. If a request for
correction is submitted, such request must be accompanied of proof of the flawed nature of the data for which
correction is asked.
You have the right to request that personal data pertaining to you will be deleted if they are no longer required in
light of the purposes outlined above. However, you need to keep in mind that a request for deletion will be eval-
uated by us against:
• overriding interests of Komatsu, Komatsu Europe or any other third party
• legal or regulatory obligations or administrative or judicial orders which may contradict such deletion
Instead of deletion you can also ask that we limit the processing of your personal data if and when (a) you con-
test the accuracy of that data, (b) the processing is illegitimate or (c) the data are no longer needed for the pur-
poses which are outlined above, but you need them to defend yourself in judicial proceedings.
You have the right to oppose the processing of personal data for the purposes (a) to (l) in section 4, but you are
required to explain your particular circumstances on which your request for opposition is based.
As explained earlier, if you wish to submit a request to exercise one or more of the rights listed in this section,
you must first and foremost contact your employer. Each request addressed to us can be sent via e-mail to
[email protected] for all data subject right matters.
An e-mail requesting to exercise a right will not be construed as consent with the processing of your personal
data beyond what is required for handling your request. Such request should clearly state and specify which
right you wish to exercise and the reasons for it, if such is required. It should also be dated and signed, and
accompanied by a digitally scanned copy of your valid identity card proving your identity.
Without prejudice to the allocation of responsibilities as outlined in section 1, we will promptly inform you of hav-
ing received this request. If the request proves valid, we will notify you as soon as reasonably possible and at
the latest thirty (30) days after having received the request.
If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via
MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you
remain unsatisfied with our response, you may file a complaint with the competent data protection authority.
KOMATSU MACHINE OPERATOR PRIVACY POLICY FOREWORD
1-6

SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
This signal word indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices that may
cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
If precautions described are not observed, the machine may be damaged or the service life
may be reduced.
This word is used for information that is useful to know.
FOREWORD SAFETY INFORMATION
1-7

NOISE EMISSION LEVELS
Two signs are attached to the machine that state the noise level produced.
•Sound pressure level at the operator’s station, measured
according to ISO 6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A weighted emission sound pressure
level at the operator's position is 2.5 dB, in accordance
with ISO 11201.
• Sound power level emitted by the machine, measured ac-
cording to ISO 6395 (Dynamic test method, simulated
working cycle).
This is the guaranteed value as specified in European di-
rective 2000/14/EC
This value includes an uncertainty of 1.5 dB.
71
108
NOISE EMISSION LEVELS FOREWORD
1-8

VIBRATION LEVEL
When used for its intended purpose, levels of vibration for the earth working machine transmitted from the oper-
ator’s seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096.
The actual acceleration value of the upper limbs is less than 2.5 m/s2. The uncertainty for this value is 0.51 m/s2
according EN 12096:1997.
The actual acceleration value for the body is less than 0.5 m/s2. The uncertainty for this value is 0.19 m/s2 ac-
cording EN 12096:1997.
These values were determined using a representative machine and measured during the typical operating con-
dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
Operating condition: V-shape loading
Guide to reduce vibration levels on machine
The following 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 (for wheeled machines), tension of crawler (for crawler machines)
• Brake and steering systems
• Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
• Remove any large rocks or obstacles.
• Fill any ditches and holes
• Site manager should provide machine operators with machine and schedule time to maintain terrain
conditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
• Adjust the seat and suspension for the weight and size of the operator
• Wear seat belt
• Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
• When pushing with bucket or blade, avoid sudden loading; load gradually
• Drive around obstacles and rough terrain conditions
• Slow down when it is necessary rough terrain
• Make the curve radius of traveling path as large as possible
• Travel at low speed then traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling
• Reduce speed to prevent bounce
• Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain.
• Operate the machine only when you are in good health
• Provide breaks to reduce long periods of sitting in the same posture
• Do not jump down from the cab or machine
• Do not repeatedly handle and lift loads
FOREWORD VIBRATION LEVEL
1-9

INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
•Digging work
•Leveling work
• Dozing work
• Loading work
For details of the work procedure, see “RECOMMENDED APPLICATIONS (3-206)”.
DIRECTIONS OF MACHINE
(A) Front
(B) Rear
(C) Left
(D) Right
(E) Bucket
(F) Operator's seat
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from
the operator's seat in the direction of travel (front) of the machine.
VISIBILITY FROM OPERATOR'S SEAT
This machine complies with the visibility standard (ISO 5006).
INTRODUCTION FOREWORD
1-10

This machine maintains a proximity visibility of a height of 1.2 m and 1.5 m at a 1 m away from the outside sur-
face of the machine, and a visibility for a radius of 12 m.
P
P
P
P
Height to evaluate the proximity visibility
Front side Left-hand side Right-hand side Rear side
1.5 m 1.5 m 1.5 m 1.2 m
FOREWORD INTRODUCTION
1-11

To assist with job site organisation during use of this machine, a visibility map is provided that shows an approxi-
mation of any masking to visibility between the 1 m rectangular boundary and the 12 m test circle.
Based upon the information supplied in the visibility map the site operator may wish to provide additional meas-
ures where it is felt necessary or provide additional instruction to personnel.
Specification of visibility map
• Machine Posture : In accordance with ISO5006
• Evaluation height : 1.2 m above the ground
• Scale-interval of the circles is 1 m.
Protective structures
This machine is equipped with a structure to protect the operator (ROPS) conforming to ISO3471.
INTRODUCTION FOREWORD
1-12

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS
EMISSION
About Engine Technology
This engine technology combines a Komatsu Diesel Particulate Filter (KDPF) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union.
• Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the
exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process
to burn the soot is performed automatically to keep the filtering performance of KDPF high.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the reagent for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, commonly referred to as AdBlue® in the European Union, that quality standards are main-
tained in accordance with DIN70070 and ISO 22241-1, to be used.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
FOREWORD ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
1-13

PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-
AL NO. PLATE
This is located at the center of the front frame on the right side of the machine.
The design of the nameplate differs according to the district.
LOCATION OF ENGINE NUMBER PLATE
This is located at the rear of the engine, on the left side of the machine.
PRODUCT INFORMATION FOREWORD
1-14

ROPS/FOPS SERIAL PLATE LOCATION
AXLE SERIAL PLATE LOCATION
This plate is located on the right of front axle and on the left of
rear axle.
TRANSMISSION SERIAL PLATE LOCATION
This plate is located in travel direction front, above the trans-
mission output.
g0047137
Komatsu Ltd.,Tokyo,Japan
SERIAL NO.
PART NO.
MODEL
PRODUCED BY
KOMATSU GERMANY GmbH, HANNOVER
FEDERAL REPUBLIC OF GERMANY FOR
g0047138
Komatsu Ltd.,Tokyo,Japan
SERIAL NO.
PART NO.
MODEL
PRODUCED BY
KOMATSU GERMANY GmbH, HANNOVER
FEDERAL REPUBLIC OF GERMANY FOR
FOREWORD PRODUCT INFORMATION
1-15

SEAT PLATE LOCATION
This plate is located in front of seat, covered by the bellows.
FLUORINATED GREENHOUSE GASES
Product contains fluorinated greenhouse gases.
SERVICE METER LOCATION
It is at the center bottom of the machine monitor.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Manufacturer name
Address Komatsu Germany GmbH Hanomag Strasse 9
30449 Hannover
Germany
g0047139
HFC-134a
GWP 1430 CO2 eq.
kg
t
09971-10111
Product contains
fluorinated
greenhouse gases
1.1
1.57
PRODUCT INFORMATION FOREWORD
1-16

Distributor name
Address
Phone/Fax
Service personnel
FOREWORD PRODUCT INFORMATION
1-17

DECLARATION OF CONFORMITY
The manufacturer:
Komatsu Germany GmbH
Hanomag Straße 9
30449 Hannover
Germany
Declares that this machine:
WA480-8*
Fulfils all the relevant provisions of following EC Directives:
Machine Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2014/30/EU
Outdoor Noise Directive 2000/14/EC amended by 2005/88/EC
Radio Equipment Directive 2014/53/EU
*: explanation of machine category
Machine category Stand for:
WA Wheel loader
DECLARATION OF CONFORMITY FOREWORD
1-18