KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 and UP) – PDF DOWNLOAD

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KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 and UP)

KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 AND UP) – PDF DOWNLOAD:

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KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 and UP)

• Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death.
• Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine.
• This manual should be kept near the machine for reference and periodically reviewed by all personnel who come across it.
• Some actions involved in operation and maintenance can cause a serious accident, if they are not performed in the manner described in this manual.
• The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual.
• Komatsu America International Company 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 features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local distributor or Komatsu America International Company before operating the machine.

Table of Contents:

KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 and UP)

MAIN MENU...........................................................................................  0
COVER...............................................................................................  1
INTRODUCTION........................................................................................  7
	FOREWORD........................................................................................  8
	SAFETY INFORMATION..............................................................................  9
	INTRODUCTION.................................................................................... 10
		INTENDED USE................................................................................ 10
		FEATURES.................................................................................... 10
		BREAKING IN A NEW MACHINE................................................................... 10
	LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................... 11
		MACHINE SERIAL NO. PLATE POSITION........................................................... 11
		ENGINE SERIAL NO. PLATE POSITION............................................................ 11
		TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................... 11
	CONTENTS........................................................................................ 12
SAFETY.............................................................................................. 21
	GENERAL PRECAUTIONS............................................................................. 22
		SAFETY RULES................................................................................ 22
		SAFETY FEATURES............................................................................. 22
		UNAUTHORIZED MODIFICATION................................................................... 22
		CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................... 23
		ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................. 23
		MOUNTING AND DISMOUNTING.................................................................... 24
		FIRE PREVENTION FOR FUEL AND OIL............................................................ 24
		PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES.............................................. 25
		ASBESTOS DUST HAZARD PREVENTION............................................................. 25
		CRUSHING OR CUTTING PREVENTION.............................................................. 25
		FIRE EXTINGUISHER AND FIRST AID KIT......................................................... 26
		PRECAUTIONS WHEN USING ROPS................................................................. 26
		PRECAUTIONS FOR ATTACHMENTS................................................................. 26
		PRECAUTION WHEN HANDLING ACCUMULATOR........................................................ 27
	PRECAUTIONS DURING OPERATION.................................................................... 28
		BEFORE STARTING ENGINE...................................................................... 28
			SAFETY AT WORKSITE...................................................................... 28
			FIRE PREVENTION......................................................................... 28
			WALK AROUND CHECK....................................................................... 28
			IN OPERATOR'S CAB....................................................................... 29
			VENTILATION FOR ENCLOSED AREAS.......................................................... 29
			PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS............................................ 29
			WHEN STARTING ENGINE.................................................................... 30
		AFTER STARTING ENGINE....................................................................... 31
			CHECKS AFTER STARTING ENGINE............................................................ 31
			PRECAUTIONS WHEN STARTING OFF........................................................... 31
			CHECK WHEN CHANGING DIRECTION........................................................... 32
			PRECAUTIONS WHEN TRAVELING.............................................................. 33
			TRAVELING ON SLOPES..................................................................... 34
			PROHIBITED OPERATIONS................................................................... 34
			PRECAUTIONS WHEN TRAVELING.............................................................. 35
			DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.................................................. 36
			ENSURE GOOD VISIBILITY.................................................................. 37
			OPERATE CAREFULLY ON SNOW............................................................... 37
			DO NOT HIT WORK EQUIPMENT............................................................... 37
			WHEN USING THE BRAKE.................................................................... 37
			WHEN TRAVELING DOWNHILL................................................................. 37
			WORKING ON LOOSE GROUND................................................................. 38
			PARKING THE MACHINE..................................................................... 38
			PRECAUTIONS IN COLD AREAS............................................................... 39
		TRANSPORTATION.............................................................................. 40
			LOADING AND UNLOADING................................................................... 40
			SHIPPING................................................................................ 40
		BATTERY..................................................................................... 41
			BATTERY HAZARD PREVENTION............................................................... 41
			STARTING WITH BOOSTER CABLES............................................................ 42
			CHARGING BATTERY........................................................................ 43
		TOWING...................................................................................... 44
			WHEN TOWING............................................................................. 44
	PRECAUTIONS FOR MAINTENANCE..................................................................... 45
		BEFORE CARRYING OUT MAINTENANCE............................................................. 45
			NOTIFICATION OF FAILURE................................................................. 45
			WARNING TAGS............................................................................ 45
			CLEAN BEFORE INSPECTION AND MAINTENANCE................................................. 45
			STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.............................. 46
			WORK EQUIPMENT SUPPORT.................................................................. 46
			PROPER TOOLS............................................................................ 47
			PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................... 47
			USE OF LIGHTING......................................................................... 47
			KEEP WORK PLACE CLEAN AND TIDY.......................................................... 47
			APPOINT A LEADER WHEN WORKING WITH OTHERS............................................... 48
			RADIATOR WATER LEVEL.................................................................... 48
			PREVENTION OF FIRE...................................................................... 48
			TURN E.C.S.S. SWITCH OFF................................................................ 48
		DURING MAINTENANCE.......................................................................... 49
			PERSONNEL............................................................................... 49
			ATTACHMENTS............................................................................. 49
			WORK UNDER THE MACHINE.................................................................. 49
			KEEP THE MACHINE CLEAN.................................................................. 49
			DO NOT DROP TOOLS OR PARTS INSIDE MACHINE............................................... 50
			PRECAUTIONS WHEN USING HAMMER........................................................... 50
			REPAIR WELDING.......................................................................... 50
			PRECAUTIONS WITH BATTERY................................................................ 50
			WHEN ABNORMALITY IS LOCATED............................................................. 50
			RULES TO FOLLOW WHEN ADDING FUEL OR OIL................................................. 51
			ROTATING FAN AND BELT................................................................... 51
			HANDLING HIGH-PRESSURE HOSES............................................................ 51
			PRECAUTION HIGH PRESSURE OIL............................................................ 51
			PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE.......... 52
			TIRE MAINTENANCE........................................................................ 53
			CHECKS AFTER INSPECTION AND MAINTENANCE................................................. 53
			WASTE MATERIALS......................................................................... 53
			WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED..................................... 53
		TIRES....................................................................................... 54
			HANDLING TIRES.......................................................................... 54
			STORING TIRES AFTER REMOVAL............................................................. 55
	POSITION FOR ATTACHING SAFETY LABELS............................................................ 56
		LOCATIONS................................................................................... 56
		LABEL TEXT.................................................................................. 57
OPERATION........................................................................................... 63
	GENERAL VIEW.................................................................................... 64
		EXTERIOR VIEW OF MACHINE.................................................................... 64
		VIEW OF CONTROLS AND GAUGES................................................................. 65
	EXPLANATION OF COMPONENTS....................................................................... 67
		METERS AND LAMPS............................................................................ 67
		SWITCHES (ALL MODELS)....................................................................... 72
		SWITCHES (MODELS WITH CAB).................................................................. 76
		CONTROL LEVERS AND PEDALS................................................................... 78
		MISCELLANEOUS............................................................................... 85
			SAFETY BAR.............................................................................. 85
			TOWING PIN.............................................................................. 85
			GREASE PUMP CLAMP AND RUBBER RING....................................................... 85
			BACKUP ALARM............................................................................ 85
		FUSES....................................................................................... 86
			FUSE CAPACITY AND NAME OF CIRCUIT....................................................... 86
			SLOW-BLOW FUSES......................................................................... 87
			STORING THIS MANUAL..................................................................... 88
			AUXILIARY POWER SOURCE.................................................................. 88
	MACHINE AND ENGINE CHECKS....................................................................... 89
		CHECKS BEFORE STARTING ENGINE............................................................... 89
			WALK-AROUND CHECKS...................................................................... 89
		CHECK BEFORE STARTING....................................................................... 92
			CHECKING AND ADDING COOLANT............................................................. 92
			CHECKING THE DUST INDICATOR............................................................. 92
			CHECKING THE BRAKE OIL TANK............................................................. 93
			CHECKING AND ADDING ENGINE OIL.......................................................... 93
			DRAINING THE FUEL-WATER SEPARATOR....................................................... 94
			DRAINING THE FUEL SEDIMENT STRAINER..................................................... 94
			CHECKING THE ELECTRICAL WIRING.......................................................... 95
			CHECKING THE FUEL LEVEL................................................................. 95
			INSPECTING THE TIRES.................................................................... 96
			INSPECTING THE RIMS..................................................................... 96
			CHECKING THE TIRE PRESSURE.............................................................. 96
			CHECKING THE MONITOR PANEL.............................................................. 97
			CHECKING THE PARKING BRAKE.............................................................. 98
			CHECKING THE WHEEL BRAKES............................................................... 98
			CHECK SOUND OF HORN AND BACKUP ALARM.................................................... 98
			CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...................................... 98
			CHECK ENGINE EXHAUST COLOR AND SOUND.................................................... 98
			CHECK OPERATION OF GAUGES............................................................... 98
			CHECK STEERING WHEEL PLAY, CHECK STEERING OPERATION..................................... 98
			CHECK THE REAR VIEW MIRROR.............................................................. 98
			CHECK LOCK OF CAB DOOR (MACHINES EQUIPPED WITH CAB)..................................... 98
		PRE-WORK SHIFT MACHINE CHECKS............................................................... 99
			ADJUSTING THE OPERATOR'S SEAT (STANDARD VERSION)........................................ 99
			ADJUSTING THE OPERATOR’S SEAT...........................................................100
			(OPTIONAL AIR-RIDE SEAT)................................................................100
			ADJUSTING THE SEAT BELT.................................................................101
			ADJUSTING THE REAR VIEW MIRRORS.........................................................101
		OPERATIONS AND CHECKS BEFORE STARTING ENGINE................................................102
	STARTING THE ENGINE.............................................................................103
		NORMAL STARTING PROCEDURES (IN COLD AND WARM CONDITIONS)....................................103
		AFTER EXTENDED SHUTDOWN OR OIL CHANGE.......................................................104
		AFTER CHANGING FUEL FILTERS.................................................................104
		AFTER RUNNING OUT OF FUEL...................................................................105
		OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................105
	OPERATING THE MACHINE...........................................................................107
		MOVING THE MACHINE..........................................................................107
		CHANGING THE GEAR SPEED.....................................................................109
		CHANGING DIRECTION (FORWARD-REVERSE)........................................................110
			AUTO-SHIFT TRANSMISSION.................................................................110
		TURNING THE MACHINE.........................................................................111
		STOPPING THE MACHINE........................................................................112
		OPERATING THE WORK EQUIPMENT................................................................113
			LIFT ARM (LEVER)........................................................................113
			BUCKET (LEVER)..........................................................................114
		PARKING THE MACHINE.........................................................................115
		CHECKS AFTER COMPLETION OF OPERATION........................................................117
		STOPPING ENGINE.............................................................................117
		CHECKS AFTER STOPPING ENGINE................................................................117
		LOCKING THE MACHINE.........................................................................118
	TRANSPORTING THE MACHINE........................................................................119
		LOADING AND UNLOADING.......................................................................119
		PRECAUTIONS FOR LOADING.....................................................................120
		PRECAUTIONS FOR LIFTING THE VEHICLE.........................................................120
			LIFTING POINT DECALS....................................................................121
			WEIGHT LIST.............................................................................121
			LIFTING PROCEDURE.......................................................................122
	TYPICAL WORK OPERATIONS.........................................................................123
		DIGGING OPERATIONS WITH ROCK PILES..........................................................123
		DIGGING OPERATIONS ON LEVEL GROUND..........................................................125
		LEVELING OPERATIONS.........................................................................126
			PUSHING OPERATIONS......................................................................126
			STANDARD LOADING OPERATIONS.............................................................127
			LOAD-AND-CARRY OPERATIONS...............................................................128
		PRECAUTIONS FOR OPERATION...................................................................128
			PERMISSIBLE WATER DEPTH.................................................................128
			IF WHEEL BRAKE DOES NOT WORK............................................................128
			PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES..............................................128
			PRECAUTIONS WHEN DRIVING MACHINE........................................................129
		ADJUSTING THE WORK EQUIPMENT POSTURE........................................................129
			ADJUSTING THE BOOM KICKOUT..............................................................129
			ADJUSTING THE BUCKET POSITIONER.........................................................130
			BUCKET LEVEL INDICATOR..................................................................130
	COLD WEATHER OPERATIONS.........................................................................131
		PRECAUTIONS DURING LOW AMBIENT TEMPERATURES.................................................131
			FUEL AND LUBRICANTS.....................................................................131
			COOLANT.................................................................................131
			BATTERY.................................................................................132
		AFTER COMPLETION OF WORK....................................................................132
		AFTER COLD WEATHER HAS PASSED...............................................................132
	LONG-TERM STORAGE...............................................................................133
		BEFORE STORAGE..............................................................................133
		DURING STORAGE..............................................................................133
		AFTER STORAGE...............................................................................133
	TROUBLESHOOTING.................................................................................134
		MACHINE RUNS OUT OF FUEL....................................................................134
		TOWING THE MACHINE..........................................................................134
			ENGINE STARTS...........................................................................135
			ENGINE DOES NOT START...................................................................135
		DISCHARGED BATTERY..........................................................................136
			BATTERY REMOVAL AND INSTALLATION........................................................137
			BATTERY CHARGING PRECAUTIONS............................................................137
			USING BOOSTER CABLES TO START THE ENGINE................................................138
	OTHER TROUBLE...................................................................................140
		ELECTRICAL SYSTEM...........................................................................140
			CHASSIS.................................................................................141
			ENGINE..................................................................................143
MAINTENANCE.........................................................................................145
	GUIDES TO MAINTENANCE...........................................................................146
	OUTLINES OF SERVICE.............................................................................148
		OUTLINE OF OIL, FUEL, COOLANT...............................................................148
			OIL.....................................................................................148
			FUEL....................................................................................149
			COOLANT.................................................................................149
			GREASE..................................................................................150
			STORING OIL AND FUEL....................................................................150
			FILTERS.................................................................................150
		FUEL INJECTION PUMP.........................................................................150
		OUTLINE OF ELECTRIC SYSTEM..................................................................151
	WEAR PARTS LIST.................................................................................152
	USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................153
		PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................................153
		ENGINE OIL SPECIFICATIONS...................................................................154
			NORMAL OPERATION........................................................................154
			ARCTIC OPERATION........................................................................154
		DIESEL FUEL SPECIFICATIONS..................................................................155
		COOLANT SPECIFICATIONS......................................................................155
			GENERAL.................................................................................155
			WATER...................................................................................155
			ANTIFREEZE..............................................................................156
			INHIBITORS/CONDITIONERS.................................................................157
			MAINTENANCE OF COOLING SYSTEM INHIBITORS................................................157
			COOLANT TESTING FOR CONDITIONER CONCENTRATION...........................................157
			REPLENISHING COOLANT CONDITIONER........................................................157
			DCA4 UNIT MAINTENANCE GUIDE.............................................................158
			COOLING SYSTEM TEST KIT.................................................................160
	STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...................................................161
		INTRODUCTION OF NECESSARY TOOLS.............................................................161
		TORQUE LIST.................................................................................162
	PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................163
		SAFETY CRITICAL PARTS.......................................................................164
	MAINTENANCE SCHEDULE CHART......................................................................167
		MAINTENANCE SCHEDULE CHART..................................................................167
	SERVICE PROCEDURES..............................................................................170
		INITIAL 250 HOURS SERVICE...................................................................170
			REPLACE FUEL FILTERS....................................................................170
			REPLACE TRANSMISSION OIL FILTER ELEMENT.................................................170
			REPLACE HYDRAULIC TANK FILTER ELEMENT...................................................170
		WHEN REQUIRED...............................................................................171
			CHECKING, CLEANING OR REPLACING THE AIR CLEANER ELEMENT.................................171
			CHECKING THE TRANSMISSION OIL LEVEL, ADDING OIL.........................................173
			CHECKING THE AXLE OIL LEVEL, ADDING OIL.................................................174
			CLEANING THE AXLE CASE BREATHER.........................................................175
			CLEANING THE RADIATOR FINS..............................................................175
			REPLACING THE BOLT-ON CUTTING EDGES.....................................................176
			REPLACING THE BUCKET TEETH (IF EQUIPPED)................................................177
			CHECKING THE AIR CONDITIONER (IF EQUIPPED)..............................................178
			CLEANING THE AIR CONDITIONER CONDENSER (IF EQUIPPED)....................................179
			CHECKING THE WINDOW WASHING FLUID.......................................................179
			CHECKING AND ADJUSTING THE PARKING BRAKE................................................180
			REPLACING A SLOW-BLOW FUSE..............................................................181
			CHECKING THE AIR INTAKE HEATER..........................................................181
		CHECKS BEFORE STARTING......................................................................182
		EVERY 50 HOURS SERVICE......................................................................182
			DRAINING WATER AND SEDIMENT FROM THE FUEL TANK..........................................182
		EVERY 100 HOURS SERVICE.....................................................................183
			CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK, ADDING OIL................................183
			CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT...................................184
			LUBRICATING.............................................................................185
		EVERY 250 HOURS SERVICE.....................................................................186
			CHANGING THE ENGINE OIL AND REPLACING THE ENGINE OIL FILTER.............................186
			CHECKING FOR LOOSE WHEEL HUB BOLTS......................................................188
			CLEANING THE AIR CONDITIONER RECIRCULATION FILTER ELEMENT...............................188
			CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION......................189
			CHECKING THE BATTERY ELECTROLYTE LEVEL..................................................190
			CHECKING THE AIR INTAKE SYSTEM..........................................................190
			LUBRICATING.............................................................................191
		EVERY 500 HOURS SERVICE.....................................................................192
			REPLACING THE FUEL FILTERS..............................................................192
			REPLACING THE TRANSMISSION OIL FILTER ELEMENT...........................................194
			LUBRICATING THE CENTER HINGE PIN........................................................195
		EVERY 1,000 HOURS SERVICE...................................................................196
			CHANGING THE TRANSMISSION CASE OIL, CLEANING THE STRAINER...............................196
			CLEANING THE TRANSMISSION CASE BREATHER.................................................197
			LUBRICATING THE FRONT, CENTER, AND REAR DRIVE SHAFTS....................................197
			ADJUSTING THE ENGINE VALVE LASH CLEARANCE...............................................198
			CHANGING THE HYDRAULIC TANK OIL, REPLACING THE FILTER ELEMENT...........................199
			CHECKING THE FAN BELT TENSION...........................................................201
			CHECKING THE FAN BELT TENSIONER BEARING AND FAN HUB BEARING; INSPECTING THE FAN BELT....201
		EVERY 2,000 HOURS SERVICE...................................................................203
			REPLACING COOLANT, FLUSHING THE COOLING SYSTEM..........................................203
			REPLACING THE HYDRAULIC TANK BREATHER ELEMENT...........................................206
			CHANGING THE AXLE OIL...................................................................206
			CHECK BRAKE DISC WEAR...................................................................207
			CHECK THE ALTERNATOR....................................................................207
			CHECK THE STARTER MOTOR.................................................................207
			CHECKING THE VIBRATION DAMPER...........................................................207
			REPLACING THE AIR CONDITIONER RECIRCULATION AND.........................................207
			FRESH AIR FILTER ELEMENTS...............................................................207
			ADJUSTING THE ENGINE VALVE LASH CLEARANCE...............................................208
			CLEANING AND CHECKING THE TURBOCHARGER..................................................210
			CLEAN PPC CIRCUIT STRAINER..............................................................210
			CHECK ACCUMULATOR GAS PRESSURE..........................................................210
		EVERY 4,000 HOURS SERVICE...................................................................210
			CHECK THE WATER PUMP....................................................................210
SPECIFICATIONS......................................................................................211
	WA120-3MC Specifications........................................................................212
OPTIONS, ATTACHMENTS................................................................................215
	AVAILABLE ATTACHMENTS...........................................................................216
	BUCKETS AND TIRES SELECTION.....................................................................217
	AIR CONDITIONING................................................................................218
		GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.............................................218
			FAN SWITCH..............................................................................218
			AIR CONDITIONER SWITCH..................................................................218
			MODE SELECTOR SWITCH....................................................................219
			FRESH/RECIRC SELECTOR SWITCH............................................................219
			TEMPERATURE CONTROL SWITCH..............................................................219
		METHOD OF OPERATION.........................................................................220
			WHEN NOT USING THE AIR CONDITIONER REGULARLY...........................................220
		COOL BOX....................................................................................220
	ECSS (Electronically-Controlled Suspension System)..............................................221
		STRUCTURE AND FUNCTION OF ECSS..............................................................221
		METHOD OF OPERATING ECSS....................................................................222
		PRECAUTIONS WHEN OPERATING ECSS SWITCH......................................................222
		ACCUMULATOR PRECAUTIONS.....................................................................223
	RADIO...........................................................................................224
		OPERATING CONTROLS..........................................................................224
		OPERATION...................................................................................225
		SETTING THE CLOCK...........................................................................227
		REMOTE CONTROL UNIT.........................................................................227
		BATTERY REPLACEMENT.........................................................................228
		PRECAUTIONS WHEN USING......................................................................228

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