KOMATSU WA320-5-M Maintenance Manual
VEAM240100
Operation & Maintenance
Manual
WHEEL LOADER
SERIAL NUMBERS WA320H50051 AND UP
DANGER
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.
-5H
NOTE
Komatsu has had the operating and maintenance instructions
translated into all the languages of the European Union.
Should you require a copy in another language please inquire
at your local dealer’s
.
FOREWORD
11
FOREWORD FOREWORD
FOREWORD 1
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.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly
and be sure that you understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have
all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
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 or purchased from
someone 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 Komatsu or your Komatsu distributor before operating
the machine.
Storage location for the Operation and Maintenance Manual:
Pocket (1) at rear of operator's seat
1-2
FOREWORD FOREWORD
EU DIRECTIVES 0.
Machines supplied by us fulfil the Directive for Machinery 89/392/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 standards
and regulations in a specific country.
Notes on subsequent installation of electrical and electronic equipment and components
Electrical and electronic equipment and/or components which have been installed subsequently, emit electromagnetic 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 disturbance
to the vehicle’s electronic system or other components. Above all, you must ensure that any subsequently installed
electrical and electronic components comply with the EMV Directive 89/336/EEC 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):
q Only equipment approved by national legislation (e.g. BZT approval for Germany) may be used
q The unit must be fixed in position
q Portable or mobile units may only be used inside the vehicles if they are connected to a fixed outside
antenna
q The transmitter unit must be spatially separated from the vehicle’s electronic system
q 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 permitted
power consumption.
1-3
SAFETY INFORMATION FOREWORD
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This word is used also to alert against unsafe practices that may cause property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
1-4
This word is used for information that is useful to know.
FOREWORD SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
For details of safety labels, see "SAFETY LABELS (2-3)".
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Komatsu cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore,
the safety messages in this manual and on the machine may
not include all possible safety precautions.
If any procedures or actions not specifically recommended or
allowed in this manual are used, it is your responsibility to take
the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions
described in this manual.
The explanations, values, and illustrations in this manual were
prepared based on the latest information available at that time.
Continuing improvements in the design of this machine can
lead to changes in detail which may not be reflected in this
manual. Consult Komatsu or your Komatsu distributor for the
latest available information of your machine or for questions
regarding information in this manual.
The numbers in circles in the illustrations correspond to the
numbers in ( ) in the text. (For example: 1 -> (1))
1-5
INTRODUCTION FOREWORD
INTRODUCTION 1
This loader is a machine with independent transmission, moving on chains or wheels. Driving in forward direction,
the loader can load or dig material using its attachments intended for loading operations (i.e. bucket).
The standard operation cycle of a loader includes filling up and loading of the bucket, transporting the material and
emptying the bucket.
INTENDED USE
If you use the machine for any other purpose than specified above, we will not accept any responsibility for safety.
All considerations concerning safety will then be up to the owner or the operating and maintenance personnel. In
any case, neither you nor any other person are/is authorised to perform work and functions explicitly prohibited in
these operating instructions.
The transport of persons in the work equipment is strictly forbidden!
For details of the operating procedure, see “WORK POSSIBLE USING WHEEL LOADER (3-86)“.
DIRECTIONS OF MACHINE 1
Front
Bucket
RightLeft
Rear
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.
1-6
FOREWORD NECESSARY INFORMATION
NECESSARY INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION 1
On the center right of the front frame.
ENGINE SERIAL NO. PLATE AND POSITION 1
This is on the side face of the engine cover on the right side of the machine.
EPA: Environmental Protection Agency, U.S.A.
1-7
NECESSARY INFORMATION FOREWORD
ROPS/FOPS-CAB SERIAL NO. PLATE
This plate is located on the right inside cab on the rear beam.
AXLE SERIAL NO. PLATE
This plate is located on the right of front axle and on the left of
rear axle.
TRANSMISSION SERIAL NO. PLATE
This plate is located in travel direction front, above the
transmission output.
SEAT OPERATOR SERIAL NO. PLATE
This plate is located in front of seat, covered by the bellows.
1-8
FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER 1
It is at the center bottom of the machine monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personnel
Phone/Fax
1-9
CONTENTS FOREWORD
CONTENTS
FOREWORD
FOREWORD....................................................................................................................................................... 1-2
SAFETY INFORMATION.................................................................................................................................... 1-4
INTRODUCTION................................................................................................................................................. 1-6
INTENDED USE ............................................................................................................................................ 1-6
DIRECTIONS OF MACHINE ......................................................................................................................... 1-6
NECESSARY INFORMATION ........................................................................................................................... 1-7
MACHINE SERIAL NO. PLATE AND POSITION .......................................................................................... 1-7
ENGINE SERIAL NO. PLATE AND POSITION ............................................................................................. 1-7
ROPS/FOPS-CAB SERIAL NO. PLATE ........................................................................................................ 1-8
AXLE SERIAL NO. PLATE ............................................................................................................................ 1-8
TRANSMISSION SERIAL NO. PLATE .......................................................................................................... 1-8
SEAT OPERATOR SERIAL NO. PLATE ....................................................................................................... 1-8
POSITION OF SERVICE METER.................................................................................................................. 1-9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................................................................................. 1-9
CONTENTS ...................................................................................................................................................... 1-10
DIMENSIONS, WEIGHTS AND OPERATING DATA ...................................................................................... 1-17
WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA............................................................... 1-17
CE-CONFORMING EQUIPMENT..................................................................................................................... 1-18
CE-CONFORMING EQUIPMENT................................................................................................................ 1-18
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-
H1900 ..................................................................................................................................................... 1-19
SAFETY
SAFETY LABELS............................................................................................................................................... 2-3
LOCATION OF SAFETY LABELS ................................................................................................................. 2-3
PRESENTATION OF SAFETY LABELS........................................................................................................ 2-4
GENERAL PRECAUTIONS ............................................................................................................................... 2-7
PRECAUTIONS FOR OPERATION ................................................................................................................. 2-17
STARTING ENGINE .................................................................................................................................... 2-17
OPERATION ................................................................................................................................................ 2-19
TRANSPORTATION .................................................................................................................................... 2-25
BATTERY..................................................................................................................................................... 2-26
TOWING ...................................................................................................................................................... 2-28
PRECAUTIONS FOR MAINTENANCE ............................................................................................................ 2-29
PRECAUTIONS WITH TIRES .......................................................................................................................... 2-36
OPERATION
GENERAL VIEW ................................................................................................................................................ 3-2
GENERAL VIEW OF MACHINE .................................................................................................................... 3-2
GENERAL VIEW OF CONTROLS AND GAUGES........................................................................................ 3-3
EXPLANATION OF COMPONENTS.................................................................................................................. 3-5
MACHINE MONITOR..................................................................................................................................... 3-5
MONITOR SYSTEM ................................................................................................................................. 3-6
TYPES OF WARNING .............................................................................................................................. 3-7
1-10
FOREWORD CONTENTS
CENTRAL WARNING LAMP .................................................................................................................... 3-7
CHARACTER DISPLAY PORTION .......................................................................................................... 3-8
EMERGENCY STOP ITEM .................................................................................................................... 3-14
CAUTION ITEMS.................................................................................................................................... 3-16
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.......................................................................... 3-18
INSPECTION AND MAINTENANCE ITEM............................................................................................. 3-19
PILOT DISPLAY PORTION .................................................................................................................... 3-22
METER DISPLAY PORTION .................................................................................................................. 3-25
OTHER FUNCTIONS OF MACHINE MONITOR.................................................................................... 3-27
SWITCHES .................................................................................................................................................. 3-30
CONTROL LEVERS, PEDALS .................................................................................................................... 3-39
STEERING TILT LOCK LEVER................................................................................................................... 3-43
CAP AND COVER WITH LOCK .................................................................................................................. 3-43
SAFETY BAR............................................................................................................................................... 3-44
TOWING PIN ............................................................................................................................................... 3-45
GREASE PUMP........................................................................................................................................... 3-45
CAB DOOR INNER LOCK ........................................................................................................................... 3-45
CAB DOOR OPEN LOCK ............................................................................................................................ 3-46
CAB WINDOW OPEN LOCK CANCEL KNOB ............................................................................................ 3-46
FUSE ........................................................................................................................................................... 3-46
FUSE CAPACITY AND NAME OF CIRCUIT.......................................................................................... 3-47
SLOW BLOW FUSE .................................................................................................................................... 3-48
POWER OUTLET ........................................................................................................................................ 3-48
STORAGE BOX ........................................................................................................................................... 3-48
AIR CONDITIONER ..................................................................................................................................... 3-49
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ....................................................... 3-49
METHOD OF OPERATION .................................................................................................................... 3-52
PRECAUTIONS WHEN USING.............................................................................................................. 3-53
HANDLING CAB WIPER ............................................................................................................................. 3-53
PREVENTING DAMAGE TO WIPER ARM BRACKET .......................................................................... 3-53
OPERATION..................................................................................................................................................... 3-54
CHECK BEFORE STARTING ENGINE, ADJUST....................................................................................... 3-54
WALK-AROUND CHECK ....................................................................................................................... 3-54
CHECK BEFORE STARTING ................................................................................................................ 3-57
ADJUSTMENT........................................................................................................................................ 3-63
OPERATIONS AND CHECKS BEFORE STARTING ENGINE .............................................................. 3-68
STARTING ENGINE .................................................................................................................................... 3-70
NORMAL STARTING ............................................................................................................................. 3-70
STARTING IN COLD WEATHER ........................................................................................................... 3-72
OPERATIONS AND CHECKS AFTER STARTING ENGINE ...................................................................... 3-74
BREAKING-IN THE MACHINE............................................................................................................... 3-74
NORMAL OPERATION .......................................................................................................................... 3-75
STOPPING ENGINE.................................................................................................................................... 3-76
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE .................................... 3-77
MOVING THE MACHINE........................................................................................................................ 3-77
CHANGING DIRECTION ........................................................................................................................ 3-79
STOPPING THE MACHINE.................................................................................................................... 3-81
TURNING..................................................................................................................................................... 3-82
EMERGENCY STEERING ..................................................................................................................... 3-83
OPERATION OF WORK EQUIPMENT ....................................................................................................... 3-84
WORK POSSIBLE USING WHEEL LOADER ............................................................................................. 3-86
DIGGING OPERATIONS........................................................................................................................ 3-86
LEVELING OPERATIONS ...................................................................................................................... 3-89
PUSHING OPERATION ......................................................................................................................... 3-89
LOAD AND CARRY OPERATIONS .......................................................................................................3-89
LOADING OPERATIONS ....................................................................................................................... 3-90
PRECAUTIONS FOR OPERATION ............................................................................................................ 3-92
PERMISSIBLE WATER DEPTH ............................................................................................................. 3-92
IF WHEEL BRAKE DOES NOT WORK.................................................................................................. 3-92
1-11
CONTENTS FOREWORD
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES .................................................................. 3-92
ADJUSTING WORK EQUIPMENT POSTURE............................................................................................ 3-94
ADJUSTING BOOM KICKOUT............................................................................................................... 3-94
ADJUSTING BUCKET POSITIONER.....................................................................................................3-95
BUCKET LEVEL INDICATOR ................................................................................................................ 3-95
PARKING MACHINE ................................................................................................................................... 3-96
CHECK AFTER STOPPING ENGINE ......................................................................................................... 3-97
CHECKS AFTER COMPLETION OF OPERATION .................................................................................... 3-97
LOCKING ..................................................................................................................................................... 3-98
HANDLING THE TIRES............................................................................................................................... 3-99
PRECAUTIONS WHEN HANDLING TIRES ........................................................................................... 3-99
TIRE PRESSURE ................................................................................................................................... 3-99
PRECAUTIONS FOR USING LOAD AND CARRY METHOD.............................................................. 3-100
TRANSPORTATION....................................................................................................................................... 3-101
TRANSPORTATION PROCEDURE .......................................................................................................... 3-101
LOADING, UNLOADING WORK WITH TRAILERS................................................................................... 3-101
LOADING.............................................................................................................................................. 3-101
SECURING MACHINE ......................................................................................................................... 3-102
UNLOADING......................................................................................................................................... 3-103
LIFTING MACHINE.................................................................................................................................... 3-104
LOCATION OF LIFTING POSITION MARK ......................................................................................... 3-105
WEIGHT TABLE ................................................................................................................................... 3-105
LIFTING PROCEDURE ........................................................................................................................ 3-106
COLD WEATHER OPERATION .................................................................................................................... 3-107
PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................... 3-107
FUEL AND LUBRICANTS .................................................................................................................... 3-107
COOLANT............................................................................................................................................. 3-107
BATTERY ............................................................................................................................................. 3-108
PRECAUTIONS AFTER COMPLETION OF WORK ................................................................................. 3-108
AFTER COLD WEATHER ......................................................................................................................... 3-109
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER ................. 3-109
LONG-TERM STORAGE................................................................................................................................3-110
BEFORE STORAGE.................................................................................................................................. 3-110
DURING STORAGE .................................................................................................................................. 3-110
AFTER STORAGE..................................................................................................................................... 3-110
TROUBLESHOOTING.................................................................................................................................... 3-111
WHEN MACHINE RUNS OUT OF FUEL...................................................................................................3-111
TOWING THE MACHINE........................................................................................................................... 3-111
WHEN ENGINE CAN BE USED........................................................................................................... 3-112
WHEN ENGINE CANNOT BE USED ................................................................................................... 3-112
IF BATTERY IS DISCHARGED ................................................................................................................. 3-113
REMOVAL AND INSTALLATION OF BATTERY.................................................................................. 3-113
PRECAUTIONS FOR CHARGING BATTERY ..................................................................................... 3-114
STARTING ENGINE WITH BOOSTER CABLE ................................................................................... 3-115
OTHER TROUBLE..................................................................................................................................... 3-117
ELECTRICAL SYSTEM ........................................................................................................................ 3-117
CHASSIS .............................................................................................................................................. 3-118
ENGINE ................................................................................................................................................ 3-120
MAINTENANCE
GUIDES TO MAINTENANCE ............................................................................................................................. 4-2
OUTLINES OF SERVICE ................................................................................................................................... 4-4
HANDLING OIL, FUEL, COOLANT, GREASE AND CARRYING OUT KOWA (Komatsu Oil Wear Analysis)4-4
OIL ............................................................................................................................................................ 4-4
FUEL......................................................................................................................................................... 4-4
COOLANT................................................................................................................................................. 4-5
1-12
FOREWORD CONTENTS
GREASE ................................................................................................................................................... 4-5
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ........................................................................... 4-5
STORING OIL AND FUEL ........................................................................................................................ 4-6
FILTERS ................................................................................................................................................... 4-6
BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS ...................................................................... 4-7
OUTLINE OF ELECTRIC SYSTEM............................................................................................................... 4-7
WEAR PARTS.................................................................................................................................................... 4-8
WEAR PARTS LIST....................................................................................................................................... 4-8
FUEL, COOLANT AND LUBRICANTS.............................................................................................................. 4-9
LUBRICATION CHART ................................................................................................................................. 4-9
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ............................................................ 4-10
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................................................................... 4-15
TORQUE LIST ............................................................................................................................................. 4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ........................................................................ 4-16
MAINTENANCE SCHEDULE CHART ............................................................................................................. 4-17
MAINTENANCE SCHEDULE CHART......................................................................................................... 4-17
SERVICE PROCEDURE .................................................................................................................................. 4-19
INITIAL 250 HOURS SERVICE ................................................................................................................... 4-19
WHEN REQUIRED ...................................................................................................................................... 4-20
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ................................................................. 4-20
DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN....................................................................... 4-22
CLEAN INSIDE OF COOLING SYSTEM................................................................................................ 4-23
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL ............................................................................ 4-26
CHECK AXLE OIL LEVEL, ADD OIL...................................................................................................... 4-27
CLEAN AXLE CASE BREATHER .......................................................................................................... 4-28
CLEAN AIR CONDITIONER CONDENSER........................................................................................... 4-29
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID .................................................................... 4-29
CLEAN RADIATOR FINS AND COOLER FINS ..................................................................................... 4-30
CLEAN TRANSFER OIL COOLER FINS ............................................................................................... 4-31
CHECK ELECTRICAL INTAKE AIR HEATER........................................................................................ 4-31
REPLACE BOLT ON CUTTING EDGE .................................................................................................. 4-32
REPLACE BUCKET TEETH................................................................................................................... 4-33
CHECK AIR CONDITIONER .................................................................................................................. 4-34
REPLACE SLOW BLOW FUSE ............................................................................................................. 4-35
SELECTION AND INSPECTION OF TIRES .......................................................................................... 4-36
CHECK BEFORE STARTING ..................................................................................................................... 4-38
EVERY 50 HOURS SERVICE ..................................................................................................................... 4-39
DRAIN WATER, SEDIMENT FROM FUEL TANK.................................................................................. 4-39
EVERY 100 HOURS SERVICE ................................................................................................................... 4-40
LUBRICATE REAR AXLE PIVOT PIN.................................................................................................... 4-40
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................................... 4-40
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ........................................................................... 4-41
EVERY 250 HOURS SERVICE ................................................................................................................... 4-42
CHECK BATTERY ELECTROLYTE LEVEL........................................................................................... 4-42
CHECK PARKING BRAKE ..................................................................................................................... 4-44
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ............................................ 4-44
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN ........................................................................ 4-45
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER ................................................ 4-46
LUBRICATING........................................................................................................................................ 4-46
EVERY 500 HOURS SERVICE ................................................................................................................... 4-48
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........................... 4-48
REPLACE FUEL FILTER CARTRIDGE ................................................................................................. 4-49
CLEAN WATER SEPARATOR STRAINER............................................................................................ 4-50
EVERY 1000 HOURS SERVICE ................................................................................................................. 4-51
CHANGE OIL IN TRANSFER CASE ...................................................................................................... 4-51
CLEAN TRANSFER CASE BREATHER ................................................................................................ 4-52
REPLACE HST OIL FILTER ELEMENT................................................................................................. 4-53
LUBRICATING........................................................................................................................................ 4-54
CHECK TIGHTENING PARTS OF TURBOCHARGER.......................................................................... 4-54
1-13
CONTENTS FOREWORD
CHECK PLAY OF TURBOCHARGER ROTOR...................................................................................... 4-54
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT........................................... 4-54
EVERY 2000 HOURS SERVICE ................................................................................................................. 4-55
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT ............................. 4-55
REPLACE HYDRAULIC TANK BREATHER ELEMENT ........................................................................ 4-56
CLEANING THE STRAINER OF THE BRAKE FILTER ......................................................................... 4-57
CHANGE AXLE OIL................................................................................................................................ 4-58
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER ..4-59
CHECK ALTERNATOR, STARTING MOTOR........................................................................................ 4-59
CHECK ENGINE VALVE CLEARANCE, ADJUST ................................................................................. 4-59
CHECK BRAKE DISC WEAR ................................................................................................................. 4-59
CLEAN AND CHECK TURBOCHARGER .............................................................................................. 4-60
CHECK ACCUMULATOR GAS PRESSURE ......................................................................................... 4-60
CHECK VIBRATION DAMPER............................................................................................................... 4-60
EVERY 4000 HOURS SERVICE ................................................................................................................. 4-61
LUBRICATING ........................................................................................................................................ 4-61
CHECK WATER PUMP .......................................................................................................................... 4-61
TECHNICAL DATA
TECHNICAL DATA ............................................................................................................................................ 5-2
NOISE EMISSION LEVELS ............................................................................................................................... 5-4
VIBRATION LEVEL............................................................................................................................................ 5-4
ATTACHMENTS, OPTIONS
SELECTING BUCKET AND TIRES ................................................................................................................... 6-2
MACHINE MONITOR WITH LOAD METER ...................................................................................................... 6-3
EXPLANATION OF COMPONENTS ............................................................................................................. 6-3
MACHINE MONITOR ............................................................................................................................... 6-3
MONITOR PANEL MODE SELECTOR SWITCH 1 .................................................................................. 6-4
MONITOR PANEL MODE SELECTOR SWITCH 2 .................................................................................. 6-4
LOAD METER CANCEL SWITCH............................................................................................................ 6-4
LOAD METER SUB TOTAL SWITCH ...................................................................................................... 6-5
MACHINE MONITOR..................................................................................................................................... 6-6
MONITOR SYSTEM ................................................................................................................................. 6-6
TYPES OF WARNING .............................................................................................................................. 6-7
CENTRAL WARNING LAMP .................................................................................................................... 6-7
CHARACTER DISPLAY PORTION .......................................................................................................... 6-8
EMERGENCY STOP ITEM .................................................................................................................... 6-14
CAUTION ITEMS .................................................................................................................................... 6-17
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.......................................................................... 6-19
INSPECTION AND MAINTENANCE ITEM............................................................................................. 6-20
PILOT DISPLAY PORTION .................................................................................................................... 6-23
METER DISPLAY PORTION .................................................................................................................. 6-26
LOAD METER......................................................................................................................................... 6-28
OTHER FUNCTIONS OF MACHINE MONITOR.................................................................................... 6-51
HANDLING MULTI-FUNCTION LEVER .......................................................................................................... 6-58
EXPLANATION OF COMPONENTS ........................................................................................................... 6-58
WORK EQUIPMENT LEVER.................................................................................................................. 6-58
DIRECTIONAL SELECTOR SWITCH .................................................................................................... 6-59
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH ............................................................... 6-59
DIRECTIONAL SELECTOR PILOT LAMP ............................................................................................. 6-60
OPERATION ................................................................................................................................................ 6-61
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE .............................................. 6-61
1-14
FOREWORD CONTENTS
CENTRAL LUBRICATION SYSTEM ............................................................................................................... 6-63
OPERATING THE CENTRAL LUBRICATION SYSTEM ............................................................................. 6-63
DISPLAY AND CONTROL UNIT ................................................................................................................. 6-63
LED-DISPLAY......................................................................................................................................... 6-64
PUSHBUTTONS..................................................................................................................................... 6-64
CHANGING THE LUBRICATION INTERVAL TIMES.................................................................................. 6-65
INDEX
INDEX ................................................................................................................................................................. 7-3
NOTES
NOTES................................................................................................................................................................ 8-2
1-15
CONTENTS FOREWORD
1-16
FOREWORD DIMENSIONS, WEIGHTS AND OPERATING DATA
DIMENSIONS, WEIGHTS AND OPERATING DATA
WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA
d
a
c
b
H
E
D
C
e
Measurements, operating data
Bucket capacity to ISO 7546 m³ 2,7
Material density t/m³ 1,8
Bucket weight without teeth kg 1.040
Static tipping load, straight kg 12.000
Static tipping load, 40° angle kg 10.355
Breakout force, hydraulic kN 134
Lifting capacity, hydraulic, on ground kN 155
Operating weight *) kg 14.040
a Reach at 45° discharge mm 990
b Dumping height at 45° discharge mm 2.855
c Lift height, hinge pin mm 3.910
d Height to upper edge of bucket mm 5.260
e Digging depth mm 105
A Overall length, bucket on ground mm 7.475
B Wheel base mm 3.030
C Bucket width mm 2.740
D Width over tyres mm 2.525
E Gauge mm 2.050
F Ground clearance mm 440
H Overall height mm 3.200
F
B
A
WA320-5Abm
These values refer to machines with 20.5 R25
L3
*) Machine without additional counterweight
1-17
CE-CONFORMING EQUIPMENT FOREWORD
CE-CONFORMING EQUIPMENT
CE-CONFORMING EQUIPMENT
CE-conforming equipment
12 345–
Type Part N o.
Bucket WA320-5H
Volume
m³
419-72-H2100 2,7 1.040
419-72-H2110 2,7 1.143
419-72-H2160 2,7 1.118
419-72-H2170 2,7 2.217
419-72-H2120 2,85 1.254
419-72-H2180 2,85 1.325
419-72-H2130 3,0 1.265
419-72-H2140 3,0 1.363
419-72-H2150 3,1 1.472
Load
Capacity
kg
Hydraulic
pressure
bar
Weight
kg
1
2
3
4
5
GK100392
1-18
FOREWORD CE-CONFORMING EQUIPMENT
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900
The responsibility for observing valid regulations in the case of
wheel loaders with "interchangeable equipment" (e.g. bucket or
fork-lift) which was not supplied from works lies with the customer which was subsequently fitted to the machine.
The directives for CE conformity and road-traffic registration
are deemed to have been fulfilled when the manufacturer of the
equipment confirms fulfilment of the form 421-93-H1900 alongside.
The certification must be sent to the customer and the wheel
loader manufacturer. The CE conformity declaration for a specific wheel loader is only legally valid once this has taken place.
The dimensions X1, X2, Y1 and Y2 must be provided by the
customer for approval for use on public roads. (valid in Germany)
The dimension Sh (smallest tyre radius) must be added to the
dimension D2.
The figure G (in kg) represents the maximum load (equipment
and operating load) which may act upon this point.
A2
D2
Y2
X2
X1
Y1
G
A1
Sh
Sh
GK100395b
1-19
CE-CONFORMING EQUIPMENT FOREWORD
1
B1
2
H2
H1
J
D1
C1
D2
Sh
B2
C2
A2
G
A1
d1=d2
3
Sh
b3
e
2
d
3
1
d
c
1-20
b4
b1
h
b2
GK100395
FOREWORD CE-CONFORMING EQUIPMENT
MANUFACTURER- SUPPLIED CE-CONFORMING
EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900
WA320-5H 421-93-H1900
A1 Distance: bucket pivoting point - front axle, horizontal
A2 Distance: bucket pivoting point - front axle, vertical
Sh Distance: road level - front axle
B1 Distance: driver's eye (1) - front axle, horizontal
B2 Distance: driver's eye (1) - front axle, vertical
C1 Distance: centre steering wheel - centre front axle,
horizontal
C2 Distance: center steering wheel - centre front axle,
vertical
D1 Distance: headlight - centre front axle, horizontal
D2 Distance: headlight - centre front axle, vertical
G Weight of equipment and working load
H1 Distance: bucket pivoting point - bucket upper edge, verti-
cal (carrying position)
H2 Distance: bucket pivoting point - vision line, vertical (carry-
ing position)
J Distance: road level - bucket bottom edge (carrying posi-
tion)
X1 Distance: cutter protection - front axle, horizontal
X2 Distance: cutter protection - road level, vertical
Y1 Distance: teeth protection - front axle, horizontal
Y2 Distance: teeth protection - road level, vertical
b1 Bucket connection dimension, boom width inside
b2 Bucket connection dimension, boom arm
b3 Bucket connection dimension, tilt rod
b4 Bucket connection dimension, temporary size
c Bucket connection dimension between d1 and d2, vertical
d1 Bucket connection dimension, bolt (3) for boom
d2 Bucket connection dimension, bolt (3) for tilt rod
e Bucket connection dimension d1 - d2, horizontally dis-
placed
h Distance: bucket bottom edge - boom bolt hole
l Distance: centre of bolt -- centre of fastening screw
A1 1930
A2 1260
Sh 700
B1 1850
B2 2131
C1 1425
C2 1766
D1 507
D2 1323
G 6400
H1 1347
H2 1651
J270
X1 2710
X2 1157
Y1 2493
Y2 1042
b1 1032
b2 108
b3 109
b4 461,5
c370
d1 75
d2 75
e0
h280
l80
1 Driver’s eye
2 Vision line
3Bolts
Tyres
Bucket
MICHELIN
20.5R25 XHA
2,7 m³
419-72-H2110
1-21
CE-CONFORMING EQUIPMENT FOREWORD
1-22
SAFETY
12
SAFETY
2-2
SAFETY SAFETY LABELS
SAFETY LABELS 2
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
Always keep all safety labels clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline. These may cause the safety labels to peel off.
Missing or damaged safety labels must be replaced. Order the new part from your Komatsu distributor.
LOCATION OF SAFETY LABELS 2
2-3
SAFETY LABELS SAFETY
PRESENTATION OF SAFETY LABELS 2
1 Precautions before starting operation, inspec-
tion and maintenance (421-93-H1250)
WARNING!
Read the Operator’s
Manual before startung operation, inspection, maintenance or
transportation.
3 Precautions when traveling in reverse
(421-93-H1360)
2 Precautions before leaving the machine
(421-93-H1290)
Sign indicates a hazard
of unexpected moving
of stopped machine.
Lower working device
to ground, move safety
lever to lock position
and take engine key
with you before leaving
machine.
4 Use Komatsu oil only
(421-93-H1390)
Sign indicates to prevere severe injury or
death
Honk to alert people
nearby. Be sure no one
is on or near machine.
Use spotter if view is
obstructed.
2-4
SAFETY SAFETY LABELS
5 Do not enter (421-93-H1320) 6 Precautions for safety bar (421-93-H1330)
Sign indicates a crush
hazard between the
articulating parts of the
vehicle.
Keep away from the
vehicle when it is
move.
7 Precautions when coolant is at high tempera-
ture (421-93-H1280)
Sign indicates a burn
hazard from spurting
hot water if radiator is
uncapped while hot.
Sign indicates a crush
hazard between the
articulating parts of
vehicle.
Lock vehicle with lock
bar to avoid movement
during maintenance,
inspection and transportation.
8 Precautions when oil is at high temperature
(421-93-H1280)
Sign indicates a burn
hazard from spurting
hot oil if hydraulic oil
tank is uncapped while
hot.
Allow coolant to cool
before removing cap.
9 Precautions when handling battery cable
(421-93-H1310)
Sign indicates an electric hazard from handling the cable.
Read manual for safe
and proper handling.
Allow hydraulic oil to
cool before removing
cap.
10 High pressure warning (421-93-H1300)
There is a hazard of
explosion injury.
Do not disassembly the
accumulator, make
holes in it, weld it cut it,
hit it, roll it or bring it
near flame.
2-5
SAFETY LABELS SAFETY
11 Do not climb on fender (421-93-H1400) 12 Do not open when engine is running
(09667-A0880)
Sign indicates a hazard
of falling.
Do not stand on this
place here.
13 “Do not come under machine“ sign
(421-93-H1370)
Sign indicates a hazard
of being run over by
moving vehicle.
Sign indicates a hazard
of rotating parts, such
as belt.
Turn off engine before
inspection and maintenance.
14 “Do not go under work equipment“ sign
(421-93-H1380)
Sign indicate a crush
hazard from falling off
of working device.
Keep a safe distance
from vehicle when it is
moving.
16 Only start machine from driver's seat
(09842-A0481)
Keep away when the
working device is
raised.
17 Safety measures before starting work
(421-93-H1340)
2-6
SAFETY GENERAL PRECAUTIONS
GENERAL PRECAUTIONS 2
SAFETY RULES
q Only trained and authorized personnel can operate and maintain the machine.
q Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severly impaired putting yourself and everyone else on your jobsite in danger.
q When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND
If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been corrected.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
q Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
q If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
q Always wear a hard hat and safety shoes. If the nature of
the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
q Check that all protective equipment functions properly
before using it.
FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any
injury or fire should occur.
q The fire extinguisher can be fastened to the inside cabin
wall on the left.
q If, in the course of certain operations, there is danger of
fire, fire extinguishers must be at hand. Familiarise with the
use of the fire extinguishers.
Fastening points
q Inform yourself on measures to be taken in the event of a
fire.
q The first-aid kit can be positioned on the right of the cabin's
interior.
q Make sure that you know all telephone numbers of the per-
sons that you need to contact in an emergency.
2-7
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