KOMATSU AVANCE PLUS WA420-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP) – PDF DOWNLOAD

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KOMATSU AVANCE PLUS WA420-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP)

KOMATSU AVANCE PLUS WA420-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP) – PDF DOWNLOAD:

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KOMATSU AVANCE PLUS WA420-3 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.  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 WA420-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 & UP)

MAIN MENU............................................................................................................................  0
COVER................................................................................................................................  1
INTRODUCTION.........................................................................................................................  4
	1. FOREWARD......................................................................................................................  5
	2. SAFETY INFORMATION............................................................................................................  6
	3. INTRODUCTION..................................................................................................................  7
		3.1 INTENDED USE.............................................................................................................  7
		3.2 FEATURES.................................................................................................................  7
		BREAKING IN A NEW MACHINE....................................................................................................  7
	4. LOCATION OF PLATES, TABLE FOR SERIAL NUMBER AND DISTRIBUTOR...................................................................  8
		4.1 MACHINE SERIAL NO. PLATE POSITION........................................................................................  8
		4.2 ENGINE SERIAL NO. PLATE POSITION.........................................................................................  8
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................................  8
	5. TABLE OF CONTENTS.............................................................................................................  9
SAFETY............................................................................................................................... 15
	6. GENERAL PRECAUTIONS........................................................................................................... 16
	7. PRECAUTIONS DURING OPERATION.................................................................................................. 22
		7.1 BEFORE STARTING ENGINE................................................................................................... 22
		7.2 OPERATING MACHINE........................................................................................................ 23
		7.3 TRANSPORTATION........................................................................................................... 32
		7.4 BATTERY.................................................................................................................. 33
		7.5 TOWING................................................................................................................... 35
	8. PRECAUTIONS FOR MAINTENANCE................................................................................................... 36
		8.1 BEFORE CARRYING OUT MAINTENANCE.......................................................................................... 36
		8.2 DURING MAINTENACE........................................................................................................ 41
		8.3 TIRES.................................................................................................................... 45
	9. SAFETY LABELS................................................................................................................. 47
OPERATION............................................................................................................................ 52
	10. GENERAL VIEW................................................................................................................. 53
		10.1 GENERAL VIEW OF MACHINE................................................................................................. 53
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 54
	11. EXPLANATION OF COMPONENTS.................................................................................................... 55
		11.1 MACHINE MONITORS........................................................................................................ 55
			11.1.1 WARNING DISPLAYS.................................................................................................. 57
			11.1.2 METER DISPLAY PORTION............................................................................................. 61
		11.2 SWITCHES................................................................................................................ 65
		11.3 CONTROL LEVERS, PEDALS.................................................................................................. 72
		11.4 STEERING COLUMN TILT LEVER.............................................................................................. 77
		11.5 CAP WITH LOCK........................................................................................................... 78
			11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK....................................................................... 78
		11.6 SAFETY BAR.............................................................................................................. 80
		11.7 TOWING PIN.............................................................................................................. 80
		11.8 GREASE PUMP............................................................................................................. 81
		11.9 BACK UP ALARM........................................................................................................... 81
		11.10 FUSE................................................................................................................... 82
			11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT................................................................................ 82
		11.11 SLOW-BLOW FUSE......................................................................................................... 83
		11.12 STORAGE FOR THIS MANUAL................................................................................................ 84
		11.13 ELECTRIC POWER (with ROPS CAB.......................................................................................... 84
	12. OPERATION.................................................................................................................... 85
		12.1 CHECKS BEFORE STARTING.................................................................................................. 85
			12.1.1 WALK AROUND CHECK................................................................................................. 85
			12.1.2 CHECK BEFORE STARTING............................................................................................. 88
			12.1.3 ADJUSTMENT BEFORE OPERATION....................................................................................... 93
			12.1.4 OPERATIONS AND CHECKS AFTER STARTING ENGINE....................................................................... 96
		12.2 STARTING ENGINE......................................................................................................... 98
			12.2.1 COLD WEATHER STARTING............................................................................................. 99
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.............................................................................100
		12.4 MOVING MACHINE..........................................................................................................101
		12.5 CHANGING GEARS..........................................................................................................103
		12.6 CHANGING DIRECTION......................................................................................................103
		12.7 TURNING.................................................................................................................104
		12.8 STOPPING MACHINE........................................................................................................105
		12.9 OPERATION OF WORK EQUIPMENT.............................................................................................106
			12.9.1 STANDARD WORK EQUIPMENT CONTROLS..................................................................................106
			12.9.2 MONO-LEVER WORK EQUIPMENT CONTROLS................................................................................108
		12.10 WORK POSSIBLE USING WHEEL LOADER.......................................................................................109
			12.10.1 DIGGING OPERATIONS...............................................................................................109
			12.10.2 LEVELING OPERATION...............................................................................................112
			12.10.3 PUSHING OPERATION................................................................................................112
			12.10.4 LOAD AND CARRY OPERATION.........................................................................................112
			12.10.5 LOADING OPERATIONS...............................................................................................113
		12.11 PRECAUTIONS FOR OPERATION..............................................................................................114
			12.11.1 PERMISSIBLE WATER DEPTH..........................................................................................114
			12.11.2 IF WHEEL BRAKE DOES NOT WORK.....................................................................................114
			12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................................................114
			12.11.4 PRECAUTIONS WHEN DRIVING MACHINE.................................................................................115
		12.12 ADJUSTING WORK EQUIPMENT POSTURE.......................................................................................116
			12.12.1 ADJUSTING BOOM KICKOUT...........................................................................................116
			12.12.2 ADJUSTING BUCKET POSITIONER......................................................................................117
			12.12.3 BUCKET LEVEL INDICATOR...........................................................................................117
		12.13 PARKING MACHINE........................................................................................................118
		12.14 CHECKS AFTER COMPLETION OF OPERATION...................................................................................119
		12.15 STOPPING ENGINE........................................................................................................119
		12.16 CHECK AFTER STOPPING ENGINE............................................................................................120
		12.17 LOCKING................................................................................................................120
		12.18 HANDLING THE TIRES.....................................................................................................121
			12.18.1 PRECAUTIONS WHEEN HANDLING TIRES.................................................................................121
			12.18.2 TIRE PRESSURE....................................................................................................121
	13. TRANSPORTATION...............................................................................................................123
		13.1 LOADING AND UNLOADING...................................................................................................123
		13.2 PRECAUTIONS FOR LOADING.................................................................................................124
		13.3 PRECAUTIONS FOR TRANSPORTATION..........................................................................................124
		13.4 LIFTING MACHINE.........................................................................................................124
			13.4.1 LOCATION FOR LIFTING POSISTION ECALS..............................................................................125
			13.4.2 WEIGHT TABLE......................................................................................................125
			13.4.3 LIFTING PROCEDURE.................................................................................................126
	14. COLD WEATHER OPERATION.......................................................................................................127
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.........................................................................................127
			14.1.1 FUEL AND LUBRICANTS...............................................................................................127
			14.1.2 COOLANT...........................................................................................................127
			14.1.3 BATTERY...........................................................................................................127
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK....................................................................................128
		14.3 AFTER COLD WEATHER......................................................................................................128
	15. LONG TERM STORAGE............................................................................................................129
		15.1 BEFORE STORAGE..........................................................................................................129
		15.2 DURING STORAGE..........................................................................................................129
		15.3 AFTER STORAGE...........................................................................................................129
	16. TROUBLESHOOTING..............................................................................................................130
		16.1 WHEN MACHINE RUNS OUT OF FUEL...........................................................................................130
		16.2 TOWING THE MACHINE......................................................................................................131
			16.2.1 WITH THE ENGINE RUNING............................................................................................132
			16.2.2 WITH THE ENGINE STOPPED...........................................................................................132
			16.2.3 RELEASING PARKING BRAKE...........................................................................................133
			16.2.4 EMERGENCY TRAVEL OPERATION........................................................................................134
		16.3 IF BATTERY IS DISCHARGED................................................................................................135
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...............................................................................135
			16.3.2 PRECAUTION FOR CHARGING BATTERY...................................................................................136
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE................................................................................137
		16.4 OTHER TROUBLE...........................................................................................................139
			16.4.1 ELECTICAL SYSTEM..................................................................................................139
			16.4.2 CHASSIS...........................................................................................................140
			16.4.3 ENGINE............................................................................................................143
MAINTENANCE..........................................................................................................................146
	17. GUIDES TO MAINTENANCE........................................................................................................147
	18. OUTLINES OF SERVICE..........................................................................................................150
		18.1 OUTLINE OF OIL, FUEL, COOLANTS..........................................................................................150
			18.1.1 OIL...............................................................................................................150
			18.1.2 FUEL..............................................................................................................151
			18.1.3 COOLANT...........................................................................................................151
			18.1.4 GREASE............................................................................................................151
			18.1.5 STORING OIL AND FUEL..............................................................................................152
			18.1.6 FILTERS...........................................................................................................152
			18.1.7 FUEL INJECTION PUMP...............................................................................................152
		18.2 OUTLINE OF ELECTRIC SYSTEM..............................................................................................153
	19. WEAR PARTS LIST..............................................................................................................154
	20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................................................................155
		20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................................155
		20.2 ENGINE OIL SPECIFICATION................................................................................................156
			20.2.1 NORMAL OPERATION..................................................................................................156
			20.2.2 ARCTIC OPERATION..................................................................................................156
		20.3 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS....157
		20.4 FINAL DRIVE OIL SPECIFICATION...........................................................................................157
		20.5 DRIVE AXLE OIL SPECIFICATIONS...........................................................................................157
		20.6 DIESEL FUEL SPECIFICATIONS..............................................................................................157
		20.7 COOLANT SPECIFICATIONS..................................................................................................158
			20.7.1 GENERAL...........................................................................................................158
			20.7.2 WATER.............................................................................................................158
			20.7.3  ANTIFREEZE.......................................................................................................158
			20.7.4 SUPPLEMENTAL COOLANT ADDITIVES....................................................................................159
	21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS................................................................................164
		21.1 INTRODUCTION OF NECESSARY TOLS..........................................................................................164
		21.2 TORQUE LIST.............................................................................................................165
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................166
	23. MAINTENANCE SCHEDULE.........................................................................................................170
		23.1 SCHEDULED MAINTENANCE CHART.............................................................................................170
	24.SERVICE PROCEDURE.............................................................................................................174
		24.1 INITIAL 250 HOURS SERVICE...............................................................................................174
		24.2 WHEN REQUIRED...........................................................................................................175
			24.2.1 CLEAN OR REPLACE AIR CLEANER ELEMENT..............................................................................175
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................................................177
			24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.....................................................................................178
			24.2.4 CLEAN THE AXLE CASE BREATHER......................................................................................179
			24.2.5 CLEAN THE RADIATOR FINS...........................................................................................179
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.................................................................................180
			24.2.7 REPLACE BUCKET TEETH..............................................................................................180
			24.2.8 CHECK AIR CONDITIONER.............................................................................................182
			24.2.9 CLEAN THE AIR CONDITIONER CONDENSER...............................................................................183
			24.2.10 OPERATE THE AIR CONDITIONER OFF SEASON...........................................................................183
			24.2.11 CHECK WINDOW WASHING FLUID, ADD FLUID............................................................................183
			24.2.12 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES)........................................................183
			24.2.13 REPLACE SLOW BLOW FUSE...........................................................................................184
		24.3 SELECTION AND INSPECTION OF RITES.......................................................................................185
		24.4 CHECKS BEFORE STARTING..................................................................................................186
			24.4.1 CHECK MONITOR PANEL...............................................................................................186
			24.4.2 CHECK COOLANT LEVEL, ADD WATER....................................................................................186
			24.4.3 CHECK FUEL LEVEL, ADD FUEL........................................................................................186
			24.4.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL........................................................................187
			24.4.5 CHECK ELECTRIC WIRING.............................................................................................188
			24.4.6 DRAIN WATER FROM FUEL WATER SEPARATOR.............................................................................188
			24.4.7 CHECK EFFECT OF PARKING BRAKE.....................................................................................189
			24.4.8 CHECK EFFECT OF BRAKE.............................................................................................189
			24.4.9 CHECK SOUND OF HORN AND BACKUP ALARM..............................................................................189
			24.4.10 CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE................................................................189
			24.4.11 CHECK ENGINE EXHAUST COLOR AND SOUND.............................................................................189
			24.4.12 CHECK OPERATION OF GAUGES........................................................................................189
			24.4.13 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION STEERING...........................................................189
			24.4.14 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE....................................................189
		24.5 EVERY 50 HOURS SERVICE..................................................................................................190
			24.5.1 DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................................................190
		24.6 EVERY 100 HOURS SERVICE.................................................................................................190
			24.6.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................................................190
			24.6.2 CLEAN ELEMENT IN AIR CONDITIONER, FRESH AIR FILTER................................................................191
			24.6.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)..........................................................................191
		24.7 EVERY 250 HOURS SERVICE.................................................................................................192
			24.7.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................................................192
			24.7.2 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN..........................................................................193
			24.7.3 CLEAN ELEMENT IN AIR CONDITIONER, RECIRCULATION FILTER............................................................193
			24.7.4 CHECK AIR CONDTIONER COMPRESSOR BELT TENSION, ADJUST..............................................................194
			24.7.5 CHECK BATTERY ELECTROLYTE LEVEL...................................................................................195
			24.7.6 LUBRICATING.......................................................................................................196
		24.8 EVERY 500 HOURS SERVICE.................................................................................................197
			24.8.1 REPLACE FUELFILTER CARTRIDGE......................................................................................197
			24.8.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...........................................................................199
			24.8.3 CORROSION RESISTOR................................................................................................200
		24.9 EVERY 1000 HOURS SERVICE................................................................................................201
			24.9.1 CHANGE OIL IN TRANSMISSION, CLEAN STRAINER........................................................................201
			24.9.2 CLEAN TRANSMISSION, CLEAN STRAINER................................................................................202
			24.9.3 LUBRICATE.........................................................................................................202
			24.9.4 CHECK ENGINE VALVE CLEARANCE, ADJUST..............................................................................204
			24.9.5 CHECK TENSION OF DRIVE BELT.......................................................................................207
			24.9.6 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING............................................................207
		24.10 EVERY 2000 HOURS SERVICE...............................................................................................209
			24.10.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH HYDRAULIC FILTER ELEMENT...............................................209
			24.10.2 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...................................................213
			24.10.3 REPLACE HYDRAULIC TANK BREATHER ELEMENT..........................................................................215
			24.10.4 CHANGE AXLE OIL..................................................................................................216
			24.10.5 CHECK BRAKE DISC WEAR............................................................................................216
			24.10.6 CHECK VIBRATION DAMPER...........................................................................................216
			24.10.7 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER AND FRESH FILTER.........................................217
			24.10.8 CLEAN PPC CIRCUIT STRAINER.......................................................................................217
			24.10.9 CHECK ACCUMULATOR GAS PRESSURE...................................................................................217
SPECIFICATIONS.......................................................................................................................218
	25. DIMENSIONS...................................................................................................................219
		25.1 WITH SMALL TIRES........................................................................................................219
		25.2 WITH LARGE TIRES........................................................................................................220
		25.3 SPECIFICATIONS..........................................................................................................221
OPTIONS, ATTACHMENTS.................................................................................................................222
	26. OPTIONAL PARTS AND ATTACHMENTS...............................................................................................223
	27. SELECTING BUCKETS AND TIRES..................................................................................................224
	28. AIR CONDITIONING.............................................................................................................225
		28.1 GENERAL LOCATIONS AND FUNCTION OFCONTROL PANEL..........................................................................225
			28.1.1 FAN SWITCH........................................................................................................225
			28.1.2 AIR CONDITIONER SWITCH............................................................................................225
			28.1.3 MODE SELECTOR SWITCH..............................................................................................226
			28.1.4 FRESH/RECIRC SELECTOR SWITCH......................................................................................226
			28.1.5 TEMPERATURE CONTROL SWITCH........................................................................................226
		28.2 METHOD OF OPERATION.....................................................................................................227
			28.2.1 WHEN NOT USING THE AIR CONDITIONER REGULARLY......................................................................227
		28.3 COOL BOX................................................................................................................227
	29. HANDLING ECSS................................................................................................................228
		29.1 STRUCTURE AND FUNCTION OF ECSS..........................................................................................228
		29.2 METHOD OF OPERATING ECSS................................................................................................229
		29.3 PRECAUTIONS WHEN OPERATING ECSS SWITCH..................................................................................229
		29.4 ACCUMULATOR PRECAUTIONS.................................................................................................230
		29.5 DISCONNECTING THE ECSS PIPING...........................................................................................231
	30 OPTION DISPLAY................................................................................................................232
		30.1 EMERGENCY STEERING PILOT LAMP...........................................................................................232
		30.2 RADIO...................................................................................................................233
			30.2.1 OPERATING CONTROLS................................................................................................233
			30.2.2 OPERATION.........................................................................................................234
			30.2.3 SETTING THE CLOCK.................................................................................................236
			30.2.4 REMOTE CONTROL UNIT...............................................................................................236
			30.2.5 BATTERY REPLACEMENT...............................................................................................237
			30.2.6 PRECAUTIONS WHEN USING............................................................................................237

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⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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