Komatsu Wheel Loader WA430-6EO Operation & Maintenance Manual SN H60266 and up – PDF DOWNLOAD

Description

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

KOMATSU WHEEL LOADER WA430-6EO OPERATION & MAINTENANCE MANUAL SN H60266 AND UP – PDF DOWNLOAD:

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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]