Komatsu Wheel Loader WA430-6EO Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu Wheel Loader WA430-6EO Operation & Maintenance Manual
1. Foreword............................................................................................... 3 1.1 Foreword.......................................................................................... 4 EU Directives..................................................................................... 5 1.2 Safety information................................................................................ 6 1.2.1 Signal words................................................................................ 6 1.2.2 Safety labels............................................................................... 8 1.3 Introduction...................................................................................... 9 1.3.1 Intended use................................................................................ 9 1.3.2 Directions of machine....................................................................... 10 1.3.3 Visibility from operator's seat............................................................. 11 1.4 Necessary information............................................................................. 12 1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position................... 12 1.4.2 Engine serial no. plate and position........................................................ 13 1.4.3 ROPS/FOPS-Cab serial no. plate.............................................................. 13 1.4.4 Axle serial no. plate....................................................................... 14 1.4.5 Transmission serial no. plate............................................................... 14 1.4.6 Seat operator serial no. plate.............................................................. 15 1.4.7 Position of service meter................................................................... 15 1.4.8 Table to enter serial no. and distributor................................................... 16 1.4.9 Declaration of conformity (for machines placed on the market as from 29th December 2009).... 16 1.5 Contents.......................................................................................... 17 1.6 Dimensions, weights and operating data............................................................ 25 1.6.1 WA430-6E0: Dimensions, weights and operating data........................................... 25 1.7 CE-Conforming equipment........................................................................... 26 1.7.1 CE-Conforming equipment..................................................................... 26 1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250........... 27 2. Safety................................................................................................. 31 2.1 Safety labels..................................................................................... 32 2.1.1 Location of safety labels................................................................... 32 2.1.2 Presentation of safety labels............................................................... 33 2.2 General precautions............................................................................... 38 2.3 Precautions for operation......................................................................... 51 2.3.1 Starting engine............................................................................. 51 2.3.2 Operation................................................................................... 53 2.3.3 Transportation.............................................................................. 61 2.3.4 Battery..................................................................................... 62 2.3.5 Towing...................................................................................... 65 2.4 Precautions for maintenance....................................................................... 66 2.5 Precautions with tires............................................................................ 76 3. Operation.............................................................................................. 79 3.1 General view...................................................................................... 80 3.1.1 General view of machine..................................................................... 80 3.1.2 General view of controls and gauges......................................................... 81 3.2 Explanation of components......................................................................... 85 3.2.1 Machine monitor............................................................................. 85 Types of warning.............................................................................. 86 Central warning lamp.......................................................................... 87 Character display portion..................................................................... 88 Emergency stop item........................................................................... 95 Caution items................................................................................. 98 Inspection and maintenance item...............................................................101 Pilot display portion.........................................................................105 Meter display portion.........................................................................111 Other functions of machine monitor............................................................114 3.2.2 Control levers, pedals......................................................................143 3.2.3 Steering tilt lock lever....................................................................150 3.2.4 Cap with lock...............................................................................151 3.2.5 Safety bar..................................................................................153 3.2.6 Towing pin..................................................................................154 3.2.7 Grease pump.................................................................................154 3.2.8 Opening cab, window door....................................................................155 3.2.9 Cab left door open knob.....................................................................155 3.2.10 Cab left door open lock....................................................................156 3.2.11 Cab window open lock.......................................................................156 Open lock cancel knob for left cab window.....................................................156 Open lock cancel knob for right cab door......................................................156 Open lock cancel knob for emergency escape right window.......................................157 3.2.12 Backup alarm...............................................................................157 3.2.13 Fuse.......................................................................................158 Fuse capacity and name of circuit.............................................................159 3.2.14 Slow blow fuse.............................................................................160 3.2.15 Location and presentation of relays........................................................161 3.2.16 Power outlet...............................................................................162 3.2.17 Air conditioner (standard).................................................................163 General locations and function of control panel...............................................163 Method of operation...........................................................................166 Precautions when using........................................................................168 Precautions for inspection and maintenance....................................................168 Cool box......................................................................................169 3.2.18 Air conditioner (automatic)................................................................170 General locations and function of control panel...............................................170 Method of operation...........................................................................175 Precautions when using........................................................................177 Precautions for inspection and maintenance....................................................177 3.2.19 Handling cab wiper.........................................................................178 Preventing damage to wiper arm bracket........................................................178 3.3 Operation.........................................................................................179 3.3.1 Check before starting engine, adjust........................................................179 Walk-around check.............................................................................179 Check before starting.........................................................................182 Adjustment....................................................................................193 Safety belt...................................................................................194 Adjust lever stand............................................................................195 Operations and checks before starting engine..................................................197 3.3.2 Starting engine.............................................................................199 Normal starting...............................................................................199 Ambient temperature range for operation and storage...........................................200 Starting in cold weather......................................................................201 Automatic warming-up operation................................................................203 3.3.3 Checks after starting engine................................................................204 Check parking brake...........................................................................204 Check brake pedal.............................................................................204 Check travel of brake pedal...................................................................204 Check for ease of starting engine, abnormal noise.............................................204 Check engine at low speed and when accelerating...............................................205 Check location of abnormalities from previous days............................................205 3.3.4 Operations after starting engine............................................................206 Breaking-in the machine.......................................................................206 Normal operation..............................................................................207 3.3.5 Stopping engine.............................................................................209 3.3.6 Check after stopping engine.................................................................209 3.3.7 Moving the machine (directional, speed), stopping the machine...............................210 Preparations for moving the machine...........................................................210 Changing gear speed...........................................................................213 Changing direction............................................................................214 Using switch to change between forward and reverse............................................216 Stopping the machine..........................................................................218 Transmission cut-off function.................................................................219 3.3.8 Turning.....................................................................................221 Emergency steering............................................................................222 3.3.9 Operation of work equipment.................................................................224 Lift arm operation............................................................................225 Bucket operation..............................................................................225 3.3.10 Work possible using wheel loader...........................................................226 Digging operations............................................................................226 Leveling operation............................................................................230 Pushing operation.............................................................................230 Load and carry operations.....................................................................231 Loading operations............................................................................231 3.3.11 Precautions for operation..................................................................233 Permissible water depth.......................................................................233 If wheel brake does not work..................................................................233 Precautions when driving up or down slopes....................................................233 3.3.12 Adjusting work equipment posture...........................................................235 Adjusting boom kickout........................................................................236 Adjusting bucket positioner...................................................................236 Bucket level indicator........................................................................237 3.3.13 Parking machine............................................................................237 3.3.14 Checks after completion of operation.......................................................239 Before stopping engine........................................................................239 After stopping engine.........................................................................239 3.3.15 Locking....................................................................................240 3.3.16 Handling the tires.........................................................................241 Precautions when handling tires...............................................................241 Tire pressure.................................................................................241 Precautions for using load and carry method...................................................243 3.4 Transportation....................................................................................244 3.4.1 Transportation procedure....................................................................244 Ensure machine stability......................................................................244 3.4.2 Loading, unloading work with trailers.......................................................244 Loading.......................................................................................245 Securing machine..............................................................................245 Unloading.....................................................................................247 3.4.3 Lifting machine.............................................................................248 Location of lifting position mark.............................................................249 Lifting procedure.............................................................................250 3.5 Cold weather operation............................................................................251 3.5.1 Precautions for low temperature.............................................................251 Fuel and lubricants...........................................................................251 Coolant.......................................................................................251 Battery.......................................................................................252 3.5.2 Precautions after completion of work........................................................253 3.5.3 After cold weather..........................................................................253 3.5.4 Warming-up operation for steering hydraulic circuit in cold weather.........................254 3.6 Long-term storage.................................................................................255 3.6.1 Before storage..............................................................................255 3.6.2 During storage..............................................................................255 3.6.3 After storage...............................................................................257 3.7 Troubleshooting...................................................................................258 3.7.1 When machine runs out of fuel...............................................................258 3.7.2 Towing the machine..........................................................................258 When engine can be used.......................................................................260 When engine cannot be used....................................................................260 Releasing parking brake.......................................................................261 Emergency travel operation....................................................................263 3.7.3 If battery is discharged....................................................................264 Removal and installation of battery...........................................................265 Precautions for charging battery..............................................................266 Starting engine with booster cable............................................................267 3.7.4 Other trouble...............................................................................270 Electrical system.............................................................................270 Chassis.......................................................................................271 Engine........................................................................................273 4. Maintenance............................................................................................275 4.1 Guides to maintenance.............................................................................276 4.2 Outlines of service...............................................................................280 4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis).......281 Oil...........................................................................................281 Fuel..........................................................................................282 Coolant and water for dilution................................................................283 Grease........................................................................................284 Carrying out KOWA (KOMATSU Oil Wear Analysis).................................................284 Storing oil and fuel..........................................................................286 Filters.......................................................................................286 4.2.2 Outline of electric system..................................................................287 4.3 Wear parts........................................................................................288 4.3.1 Wear parts list.............................................................................288 4.4 Fuel, coolant and lubricants......................................................................290 4.4.1 Lubrication chart...........................................................................292 4.4.2 Use of fuel, coolant and lubricants according to ambient temperature........................293 4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil.........295 4.5 Standard tightening torques for bolts and nuts....................................................296 4.5.1 Torque list.................................................................................296 4.6 Periodic replacement of safety critical parts.....................................................298 4.7 Maintenance schedule chart........................................................................300 4.7.1 Maintenance schedule chart..................................................................300 4.8 Replace injector assembly.........................................................................303 4.9 Service procedure.................................................................................304 4.9.1 Initial 50 hours service (only after the first 50 hours)....................................304 Check for loose wheel hub bolts, tighten......................................................304 4.9.2 Initial 250 hours service (only after the first 250 hours)..................................304 Replace transmission oil filter cartridge.....................................................304 Replace hydraulic tank filter element.........................................................304 4.9.3 Initial 1000 hours service (only after the first 1000 hours)................................304 Check engine valve clearance, adjust..........................................................304 4.9.4 When required...............................................................................305 Clean, replace air cleaner element............................................................305 Clean inside of cooling system................................................................308 Check transmission oil level, add oil.........................................................312 Check axle oil level, add oil.................................................................313 Clean axle case breather......................................................................314 Clean air conditioner condenser...............................................................315 Check window washing fluid level, add fluid...................................................315 Clean radiator fins and cooler fins...........................................................316 Turn, replace bolt on cutting edge............................................................320 Replace bucket teeth..........................................................................321 Check air conditioner.........................................................................322 Replace slow blow fuse........................................................................323 Checking function of accumulator..............................................................324 Selection and inspection of tires.............................................................325 4.9.5 Check before starting.......................................................................327 Check before starting.........................................................................327 4.9.6 Every 50 hours service......................................................................327 Drain water, sediment from fuel tank..........................................................327 4.9.7 Every 100 hours service.....................................................................328 Lubricate rear axle pivot pin.................................................................328 Check oil level in hydraulic tank, add oil....................................................328 Clean element in air conditioner fresh air filter.............................................329 4.9.8 Every 250 hours service.....................................................................330 Check battery electrolyte level...............................................................330 Check parking brake...........................................................................333 Check air conditioner compressor belt tension, adjust.........................................333 Check for loose wheel hub bolts, tighten......................................................334 Clean element in air conditioner recirculation filter.........................................335 Checking function of accumulator..............................................................336 Lubricating...................................................................................337 4.9.9 Every 500 hours service.....................................................................338 Change oil in engine oil pan, replace engine oil filter cartridge.............................338 Replace fuel pre-filter cartridge.............................................................340 4.9.10 Every 1000 hours service...................................................................343 Replace fuel main filter cartridge............................................................343 Change oil in transmission case and transmission oil filter cartridge, clean strainer.........346 Clean transmission case breather..............................................................347 Lubricating...................................................................................347 Check of engine air intake piping clamps for looseness........................................348 Check alternator driving belt tension and replacement.........................................348 Replace corrosion resistor cartridge3.........................................................348 4.9.11 Every 2000 hours service...................................................................349 Change oil in hydraulic tank, replace hydraulic filter element................................349 Replace hydraulic tank breather element.......................................................352 Change axle oil...............................................................................353 Replace element in air conditioner recirculation air filter, fresh air filter.................354 Check brake disc wear.........................................................................354 Checking function of accumulator..............................................................356 Check alternator..............................................................................357 Check engine valve clearance, adjust..........................................................357 Check vibration damper........................................................................357 4.9.12 Every 4000 hours service...................................................................358 Lubricating...................................................................................358 Check water pump..............................................................................359 Check starting motor..........................................................................359 Check air conditioner compressor, adjust......................................................359 Checking for looseness of high-pressure clamp, hardening of rubber............................360 Checking for missing fuel spray prevention cap, hardening of rubber...........................361 4.9.13 Every 8000 hours service...................................................................362 Replace high-pressure piping clamp............................................................362 Replace injector nozzle tip...................................................................362 5. Technical Data.........................................................................................363 5.1 Technical data....................................................................................364 5.2 Noise emission levels.............................................................................366 5.3 Vibration level...................................................................................367 Guide to reduce vibration levels on machine.......................................................368 5.4 Limit values for slopes...........................................................................370 6. Attachments, Options...................................................................................371 6.1 Selecting bucket and tires........................................................................372 6.2 Handling torque converter lock-up.................................................................373 6.2.1 General locations...........................................................................374 6.2.2 Method of operation.........................................................................376 6.2.3 Warning/limit functions for travel speed....................................................377 Travel speed warning function.................................................................377 Travel speed limit function...................................................................377 6.3 Handling machines equipped with KOMTRAX...........................................................378 6.3.1 Basic precautions...........................................................................379 6.4 Joystick steering system..........................................................................380 6.4.1 Components..................................................................................380 6.4.2 Structure and function......................................................................383 Operation using joystick lever and operation using steering wheel.............................384 Getting in or out.............................................................................385 Adjustment of joystick console................................................................386 6.4.3 Operation method of joystick steering system................................................387 6.5 Multi-function lever (with/without auxiliary control lever).......................................390 6.5.1 Explanation of components...................................................................390 6.5.2 Operation...................................................................................395 Using switch to change between forward and reverse............................................395 6.6 3-lever control...................................................................................397 6.6.1 Explanation of components...................................................................397 6.7 Hydraulic quick coupler (operation with lever)....................................................400 6.7.1 Installing the attachment...................................................................400 6.7.2 Removal and installation of the attachment..................................................403 6.7.3 Precautions for use.........................................................................403 6.7.4 Precautions when removing the attachment....................................................403 6.8 Hydraulic quick coupler (operation with switch)...................................................404 6.8.1 Removing the attachment.....................................................................404 6.8.2 Installing the attachment...................................................................405 6.8.3 Removal and installation of the attachment..................................................407 6.8.4 Precautions for use.........................................................................407 6.8.5 Precautions when removing the attachment....................................................407 6.9 Central lubrication system........................................................................408 6.9.1 Operating the central lubrication system....................................................408 6.9.2 Display and control unit....................................................................408 LED-display...................................................................................409 Pushbuttons...................................................................................409 6.9.3 Changing the lubrication interval times.....................................................410 6.10 Cold area kit....................................................................................411 7. Index..................................................................................................413 7.1 Index.............................................................................................414 8. Notes..................................................................................................419
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DESCRIPTION:
Komatsu Wheel Loader WA430-6EO Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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