KOMATSU AVANCE PLUS WA320-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP) – PDF DOWNLOAD

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KOMATSU AVANCE PLUS WA320-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP)

KOMATSU AVANCE PLUS WA320-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP) – PDF DOWNLOAD:

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KOMATSU AVANCE PLUS WA320-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP)

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor.
• If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual

Table of Contents:

KOMATSU AVANCE PLUS WA320-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP)

MAIN MENU............................................................................................................................  0
INTRODUCTION.........................................................................................................................  4
	1. FOREWORD......................................................................................................................  5
	2. SAFETY INFORMATION............................................................................................................  6
	3. INTRODUCTION..................................................................................................................  7
		3.1 INTENDED USE.............................................................................................................  7
		3.2 FEATURES.................................................................................................................  7
		3.3 BREAKING IN A NEW MACHINE................................................................................................  7
	4. LOCATION OF PLATE, TABLE FOR SERIAL NUMBERS AND DISTRIBUTOR...................................................................  8
		4.1 MACHINE SERIAL NUMBER PLATE POSITION.....................................................................................  8
		4.2 ENGINE SERIAL NUMBER POSITION............................................................................................  8
		4.3 TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR.............................................................................  8
	5. TABLE OF CONTENTS.............................................................................................................  9
SAFETY............................................................................................................................... 14
	6. GENERAL PRECAUTIONS........................................................................................................... 15
	7. PRECAUTIONS DURING OPERATION.................................................................................................. 21
		7.1 BEFORE STARTING ENGINE................................................................................................... 21
		7.2 OPERATING MACHINE........................................................................................................ 22
		7.3 TRANSPORTATION........................................................................................................... 31
		7.4 BATTERY.................................................................................................................. 32
		7.5 TOWING................................................................................................................... 34
	8. PRECAUTIONS FOR MAINTENANCE................................................................................................... 35
		8.1 BEFORE CARRYING OUT MAINTENANCE.......................................................................................... 35
		8.2 DURING MAINTENANCE....................................................................................................... 40
		8.3 TIRES.................................................................................................................... 44
OPERATION............................................................................................................................ 51
	10. GENERAL VIEW................................................................................................................. 52
		10.1 GENERAL VIEW OF MACHINE................................................................................................. 52
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 53
	11. EXPLANATION OF COMPONENTS.................................................................................................... 54
		11.1 MACHINE MONITORS........................................................................................................ 54
			11.1.1 WARNING DISPLAYS.................................................................................................. 56
			11.1.2 METER DISPLAY PORTION............................................................................................. 60
		11.2 SWITCHES................................................................................................................ 64
		11.3 CONTROL LEVERS, PEDALS.................................................................................................. 71
		11.4 STEERING COLUMN TILT LEVER.............................................................................................. 76
		11.5 CAP WITH LOCK........................................................................................................... 77
			11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK....................................................................... 77
		11.6 SAFETY BAR.............................................................................................................. 79
		11.7 TOWING PIN.............................................................................................................. 79
		11.8 GREASE PUMP............................................................................................................. 80
		11.9 BACK UP ALARM........................................................................................................... 80
		11.10 FUSE................................................................................................................... 81
			11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT................................................................................ 81
		11.11 SLOW-BLOW FUSE......................................................................................................... 82
		11.12 STORAGE FOR THIS MANUAL................................................................................................ 83
		11.13 ELECTRIC POWER (WITH ROPS CAB)......................................................................................... 83
	12. OPERATION.................................................................................................................... 84
		12.1 CHECKS BEFORE STARTING.................................................................................................. 84
			12.1.1 WALK AROUND CHECK................................................................................................. 84
			12.1.2 CHECK BEFORE STARTING............................................................................................. 87
			12.1.3 ADJUSTMENT BEFORE OPERATION....................................................................................... 92
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...................................................................... 95
		12.2 STARTING ENGINE......................................................................................................... 97
			12.2.1 COLD WEATHER STARTING............................................................................................. 98
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................................................. 99
		12.4 MOVING MACHINE..........................................................................................................100
		12.5 CHANGING GEARS..........................................................................................................102
		12.6 CHANGING DIRECTION......................................................................................................102
		12.7 TURNING.................................................................................................................103
		12.8 STOPPING MACHINE........................................................................................................104
		12.9 OPERATION OF WORK EQUIPMENT.............................................................................................105
			12.9.1 STANDARD WORK EQUIPMENT CONTROLS..................................................................................105
			12.9.2 MONO LEVER WORK EQUIPMENT CONTROLS................................................................................107
		12.10 WORK POSSIBLE USING WHEEL LOADER.......................................................................................108
			12.10.1 DIGGING OPERATIONS...............................................................................................108
			12.10.2 LEVELING OPERATIONS..............................................................................................111
			12.10.3 PUSHING OPERATION................................................................................................111
			12.10.4 LOAD AND CARRY OPERATIONS........................................................................................111
			12.10.5 LOADING OPERATIONS...............................................................................................112
		12.11 PRECAUTIONS FOR OPERATION..............................................................................................113
			12.11.1 PERMISSIBLE WATER DEPTH..........................................................................................113
			12.11.2 IF WHEEL BRAKE DOES NOT WORK.....................................................................................113
			12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................................................113
			12.11.4 PRECAUTIONS WHEN DRIVING MACHINE.................................................................................114
		12.12 ADJUSTING WORK EQUIPMENT POSTURE.......................................................................................115
			12.12.1 ADJUSTING BOOM KICKOUT[DIRECT.QUERY(KOMATSU,4D94E_1A,|000000,)]..................................................115
			12.12.2 ADJUSTING BUCKET POSITIONER......................................................................................116
			12.12.3 BUCKET LEVEL INDICATOR...........................................................................................116
		12.13 PARKING MACHINE........................................................................................................117
		12.14 CHECKS AFTER COMPLETION OF OPERATION...................................................................................118
		12.15 STOPPING ENGINE........................................................................................................118
		12.16 CHECK AFTER STOPPING ENGINE............................................................................................118
		12.17 LOCKING................................................................................................................119
		12.18 HANDLING THE TIRES.....................................................................................................120
			12.18.1 PRECAUTIONS WHEN HANDLING TIRES..................................................................................120
			12.18.2 TIRE PRESSURE....................................................................................................120
	13. TRANSPORTATION...............................................................................................................122
		13.1 LOADING, UNLOADING WORK.................................................................................................122
		13.2 PRECAUTIONS FOR LOADING.................................................................................................122
		13.3 PRECAUTIONS FOR TRANSPORTATION..........................................................................................123
		13.4 LIFTING MACHINE.........................................................................................................123
	14. COLD WEATHER OPERATION.......................................................................................................126
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.........................................................................................126
			14.1.1 FUEL AND LUBRICANTS...............................................................................................126
			14.1.2 COOLANT...........................................................................................................126
			14.1.3 BATTERY...........................................................................................................126
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK....................................................................................127
		14.3 AFTER COLD WEATHER......................................................................................................127
	15. LONG TERM STORAGE............................................................................................................128
		15.1 BEFORE STORAGE..........................................................................................................128
		15.2 DURING STORAGE..........................................................................................................128
		15.3 AFTER STORAGE...........................................................................................................128
	16. TROUBLESHOOTING..............................................................................................................129
		16.1 WHEN MACHINE RUNS OUT OF FUEL...........................................................................................129
		16.2 TOWING THE MACHINE......................................................................................................130
			16.2.1 WITH THE ENGINE RUNNING...........................................................................................131
			16.2.2 WITH THE ENGINE STOPPED...........................................................................................131
			16.2.3 RELEASING PARKING BRAKE...........................................................................................132
			16.2.4 EMERGENCY TRAVEL OPERATION........................................................................................133
		16.3 IF BATTERY IS DISCHARGED................................................................................................134
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...............................................................................134
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY..................................................................................135
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE................................................................................136
		16.4 OTHER TROUBLE...........................................................................................................138
			16.4.1 ELECTRICAL SYSTEM.................................................................................................138
			16.4.2 CHASSIS...........................................................................................................139
			16.4.3 ENGINE............................................................................................................142
MAINTENANCE..........................................................................................................................144
	17. GUIDES TO MAINTENANCE........................................................................................................145
	18. OUTLINES TO MAINTENANCE......................................................................................................148
		18.1 OUTLINE OF OIL, FUEL, COOLANT...........................................................................................148
			18.1.1 OIL...............................................................................................................148
			18.1.2 FUEL..............................................................................................................149
			18.1.3 COOLANT...........................................................................................................149
			18.1.4 GREASE............................................................................................................149
			18.1.5 STORING OIL AND FUEL..............................................................................................150
			18.1.6 FILTERS...........................................................................................................150
		18.2 OUTLINE OF ELECTRIC SYSTEM..............................................................................................151
	19. WEAR PARTS LIST..............................................................................................................152
	20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................................................................153
		20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................................153
		20.2 ENGINE OIL SPECIFICATIONS...............................................................................................155
			20.2.1 NORMAL OPERATION..................................................................................................155
			20.2.2 ARCTIC OPERATION..................................................................................................155
		20.3 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS....156
		20.4 DRIVE AXLE OIL SPECIFICATIONS...........................................................................................156
		20.5 DIESEL FUEL SPECIFICATIONS..............................................................................................156
		20.6 COOLANT SPECIFICATIONS..................................................................................................156
			20.6.1 GENERAL...........................................................................................................157
			20.6.2 WATER.............................................................................................................157
			20.6.3 ANTIFREEZE........................................................................................................158
			20.6.4 SUPPLEMENTAL COOLANT ADDITIVES....................................................................................159
	21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS................................................................................163
		21.1 INTRODUCTION OF NECESSARY TOOLS.........................................................................................163
		21.2 TORQUE LIST.............................................................................................................164
	22. PERIODIC REPLACEMENT OF SFETY CRITICAL PARTS.................................................................................165
	23. MAINTENANCE SCHEDULE.........................................................................................................169
		23.1 SCHEDULED MAINTENANCE CHART.............................................................................................169
	24. SERVICE PROCEDURE............................................................................................................173
		24.1 INTIAL 250 HOURS SERVICE................................................................................................173
		24.2 WHEN REQUIRED...........................................................................................................174
			24.2.1 CLEAN OR REPLACE AIR CLEANER ELEMENT..............................................................................174
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................................................176
			24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.....................................................................................177
			24.2.4 CLEAN THE AXLE CASE BREATHER......................................................................................178
			24.2.5 CLEAN THE RADIATOR FINS...........................................................................................178
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.................................................................................179
			24.2.7 REPLACE BUCKET TEETH..............................................................................................180
			24.2.8 CHECK AIR CONDITIONER.............................................................................................181
			24.2.9 CLEAN THE AIR CONDITIONER CONDENSER...............................................................................182
			24.2.10 OPERATE THE AIR CONDITONER OFF SEASON............................................................................182
			24.2.11 CHECK WINDOW WASHING FLUID, ADD FLUID............................................................................182
			24.2.12 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2PALCES..........................................................182
			24.2.13 REPLACE SLOW BLOW FUSE...........................................................................................183
			24.2.14 SELECTION AND INSPECTION OF TIRES................................................................................183
		24.3 CHECK BEFORE STARTING...................................................................................................185
			24.3.1 CHECK MONITOR PANEL...............................................................................................185
			24.3.2 CHECK COOLANT LEVEL, ADD WATER....................................................................................185
			24.3.3 CHECK FUEL LEVEL, ADD WATER.......................................................................................185
			24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD WATER......................................................................186
			24.3.5 CHECK ELECTRIC WIRING.............................................................................................187
			24.3.6 DRAIN WATER FROM FUEL WATER SEPARATOR.............................................................................187
			24.3.7 CHECK EFFECT OF PARKING BRAKE.....................................................................................188
			24.3.8 CHECK EFFECT OF BRAKE.............................................................................................188
			24.3.9 CHECK SOUND OF HORN AND BACKUP ALARM..............................................................................188
			24.3.10 CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE................................................................188
			24.3.11 CHECK ENGINE EXHAUST COLOR AND SOUND.............................................................................188
			24.3.12 CHECK OPERATION OF GUA...........................................................................................188
			24.3.13 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING........................................................188
			24.3.14 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE....................................................188
		24.4 EVERY 50 HOURS SERVICE..................................................................................................189
			24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................................................189
		24.5 EVERY 100 HOURS SERVICE.................................................................................................189
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................................................189
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.................................................................190
			24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)..........................................................................190
		24.6 EVERY 250 HOURS SERVICE.................................................................................................191
			24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILETER CARTRIDGE................................................191
			24.6.2 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN..........................................................................192
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.............................................................193
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.............................................................193
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...................................................................................194
			24.6.6 CORROSION RESISTOR................................................................................................195
			24.6.7 LUBRICATING.......................................................................................................196
		24.7 EVERY 500 HOURS SERVICE.................................................................................................197
			24.7.1 REPLACE FUEL FILTER...............................................................................................197
			24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...........................................................................199
			24.7.3 LUBRICATE CENTER DRIVE SHAFT SPLINE (1 PLACE).....................................................................199
		24.8 EVERY 1000 HOURS SERVICE................................................................................................200
			24.8.1 CHANGE OIL IN TRANSMISSION, CLEAN STRAINER........................................................................200
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..................................................................................201
			24.8.3 LUBRICATE.........................................................................................................201
			24.8.4 CHECK ENGINE VALVE CLEARANCE, ADJUST..............................................................................203
			24.8.5 CHECK TENSION OF DRIVE BELT.......................................................................................206
			24.8.6 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING............................................................206
		24.9 EVERY 2000 HOURS SERVICE................................................................................................208
			24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM..............................................................208
			24.9.2 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT....................................................212
			24.9.3 REPLACE HYDRAULIC TANK BREATHER ELEMENT...........................................................................214
			24.9.4 CHANGE AXLE OIL...................................................................................................215
			24.9.5 CHECK BRAKE DISC WEAR.............................................................................................215
			24.9.6 CHECK VIBRATION DAMPER............................................................................................215
			24.9.7 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULAION FILTER AND FRESH FILTER...........................................216
			24.9.8 CLEAN PPC CIRCUIT STRAINER........................................................................................216
			24.9.9 CHECK ACCUMULATOR GAS PRESSURE....................................................................................216
SPECIFICATIONS.......................................................................................................................217
	25.  WA320-3MC...................................................................................................................218
OPTIONS, ATTACHMENTS.................................................................................................................220
	26. OPTIONAL PARTS AND ATTACHMENTS...............................................................................................221
	27. SELECTING BUCKETS AND TIRES..................................................................................................222
	28. AIR CONDITIONING.............................................................................................................223
		28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.........................................................................223
			28.1.1 FAN SWITCH........................................................................................................223
			28.1.2 AIR CONDITIONER SWITCH............................................................................................223
			28.1.3 MODE SELECTOR SWITCH..............................................................................................224
			28.1.4 FRESH/RECIRC SELECTOR SWITCH......................................................................................224
			28.1.5 TEMPERATURE CONTROL SWITCH........................................................................................224
		28.2 METHOD OF OPERATION.....................................................................................................225
			28.2.1 WHEN NOT USING THE AIR CONDITIONER REGULARLY......................................................................225
		28.3 COOL BOX................................................................................................................225
	29. HANDLING ECSS................................................................................................................226
		29.1 STRUCTURE AND FUNCTION OF ECSS..........................................................................................226
		29.2 METHOD OF OPERATING ECSS................................................................................................227
		29.3 PRECAUTIONS WHEN OPERATING ECSS SWITCH..................................................................................227
		29.4 ACCUMULATOR PRECAUTIONS.................................................................................................228
	30. OPTION DISPLAY...............................................................................................................229
		30.1 EMERGENCY STEERING PILOT LAMP...........................................................................................229
		30.2 RADIO...................................................................................................................230
			30.2.1 OPERATING CONTROLS................................................................................................230
			30.2.2 OPERATION.........................................................................................................231
			30.2.3 SETTING THE CLOCK.................................................................................................233
			30.2.4 REMOTE CONTROL UNIT...............................................................................................233
			30.2.5 BATTERY REPLACEMENT...............................................................................................234
			30.2.6 PRECAUTIONS WHEN USING............................................................................................234

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