Komatsu WA420-3 Manual

CEAM003701
Operation&Maintenance
Manual
-3
WHEEL LOADER
SERIAL NUMBERS WA420-3MC A31001 and up
ENGINE 6D114E-1
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2016 Komatsu
Printed in U.S.A
April 2016 Komatsu America Corp.

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WA420-3MC0-0
INTRODUCTION
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TABLE OF CONTENTS
WA420-3MC 0-1
1. FOREWORD
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 andhave 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.
WARNING
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.
See safety rules in SAFETY INFORMATION on page 0-2 and in SAFETY starting page 1-1.
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TABLE OF CONTENTS
WA420-3MC0-2
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the
machine before performing maintenance and machine operations.
To identify safety messages in thismanual and on machine product graphics, the following signal words are used.
DANGER! - This word is used on safety messages and product graphics where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages and product graphics usually describe precautions that must be taken
to avoid the hazard. Failure to avoid this hazard may also result in serious damage
to the machine.
WARNING! - This word is used on safety messages and product graphics where there is a
potentially dangerous situation, which could result in serious injury or death if the
hazard is not avoided. These safety messages and product graphics usually
describe precautions that must be taken to avoid the hazard. Failure to avoid this
hazard may also result in serious damage to the machine.
CAUTION! - This word is used on safety messages and product graphics for hazards, which
could result in minor or moderate injury if the hazard is not avoided. These safety
messages and product graphics might also use this word for hazards where the
only result could be damage to the machine.
NOTE - This word is used for precautions that must be taken to avoid actions, which could
shorten the life of the machine.
Safety precautions are described in SAFETY beginning on page 1-1.
Komatsu America International Company cannot predict every circumstance that mightinvolve a potential hazard in
operationand maintenance. Therefore the safety message in this manual and on the machine may not include all
possiblesafety precautions. If any procedures or actions not specifically recommended or allowed in this manual are
used, you must be sure that you and others can do such procedures and actions safely and without damaging the
machine. If you are unsure about the safety of some procedures, contact your local distributor or Komatsu America
International Company.
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TABLE OF CONTENTS
WA420-3MC 0-3
3. INTRODUCTION
3.1 INTENDED USE
This WHEEL LOADER is designed to be used mainly for the following work:
Digging
Leveling
Pushing
Loading
For details of the operating procedures, SEE "12.10 WORK POSSIBLE USING WHEEL LOADER" on page 2-58
3.2 FEATURES
Curved glass and improved sealing for reduced noise, low vibration cab, viscous mount.
Console and steering post with unencumbered foot area providing the same comfort level as an automobile.
Fully hydraulic brake system, which does not require draining water or concerns of rust and freezing.
Maintenance-free, wet-type disc parking brake (acts also as emergency brake).
Large capacity pump and 2-stage hydraulic system for reduced cycle time and increased productivity.
One-touch panel control and optional air conditioner with new refrigerant.
Full fender system available to help prevent mud or water from splashing on or around the machine.
3.3 BREAKING IN A NEW MACHINE
Your machine has been thoroughly adjusted and tested before shipment. However, operating the machine under
severe conditions at the beginning can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter).
During break in:
After starting, let the engine idle for five minutes to allow proper engine warm-up prior to actual operation.
Avoid operation with heavy loads or at high speeds.
Avoid sudden starts or acceleration, unnecessarily abrupt stops and sharp steering except in cases of
emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply
when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this
manual, Komatsu America International Company cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstance.
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TABLE OF CONTENTS
WA420-3MC0-4
4. LOCATION OF PLATES, TABLE FOR SERIAL NUMBER AND
DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
(A) Position of plate
On the center right of the front frame.
(B) Position of stamp
This is stamped on the centerof the front frame on the right
hand side of the machine.
4.2 ENGINE SERIAL NO. PLATE POSITION
Position of plate
On the upper right of the cylinder block, when seen from the
fan side.
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Address: Phone:
Service personnel for your machine:
REMARKS
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TABLE OF CONTENTS
WA420-3MC 0-5
5. TABLE OF CONTENTS
1. FOREWORD ............................................................................0-2
2. SAFETY INFORMATION ...................................................................0-3
3. INTRODUCTION .........................................................................0-4
3.1 INTENDED USE ...................................................................0-4
3.2 FEATURES .......................................................................0-4
3.3 BREAKING IN A NEW MACHINE .....................................................0-4
4. LOCATION OF PLATES, TABLE FOR SERIAL NUMBER AND DISTRIBUTOR .......................0-5
4.1 MACHINE SERIAL NO. PLATE POSITION ..............................................0-5
4.2 ENGINE SERIAL NO. PLATE POSITION ...............................................0-5
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ....................................0-5
6. GENERAL PRECAUTIONS .................................................................1-2
7. PRECAUTIONS DURING OPERATION .......................................................1-8
7.1 BEFORE STARTING ENGINE ........................................................1-8
7.2 OPERATING MACHINE .............................................................1-9
7.3 TRANSPORTATION ...............................................................1-18
7.4 BATTERY .......................................................................1-19
7.5 TOWING ........................................................................1-21
8. PRECAUTIONS FOR MAINTENANCE .......................................................1-22
8.1 BEFORE CARRYING OUT MAINTENANCE ...........................................1-22
8.2 DURING MAINTENANCE ..........................................................1-27
8.3 TIRES ..........................................................................1-31
9. SAFETY LABELS ........................................................................1-33
10. GENERAL VIEW .........................................................................2-2
10.1 GENERAL VIEW OF MACHINE.......................................................2-2
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ........................................2-3
11. EXPLANATION OF COMPONENTS ..........................................................2-4
11.1 MACHINE MONITORS ..............................................................2-4
11.1.1 WARNING DISPLAYS ...........................................................2-6
11.1.2 METER DISPLAY PORTION .....................................................2-10
11.2 SWITCHES ......................................................................2-14
11.3 CONTROL LEVERS, PEDALS ......................................................2-21
11.4 STEERING COLUMN TILT LEVER ...................................................2-26
11.5 CAP WITH LOCK .................................................................2-27
11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK............................2-27
11.6 SAFETY BAR ....................................................................2-29
11.7 TOWING PIN.....................................................................2-29
11.8 GREASE PUMP ..................................................................2-30
11.9 BACK UP ALARM .................................................................2-30
11.10 FUSE ...........................................................................2-31
11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT ........................................2-31
11.11 SLOW-BLOW FUSE ...............................................................2-32
11.12 STORAGE FOR THIS MANUAL .....................................................2-33
11.13 ELECTRIC POWER (with ROPS CAB.................................................2-33
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TABLE OF CONTENTS
WA420-3MC0-6
12. OPERATION ............................................................................2-34
12.1 CHECKS BEFORE STARTING ......................................................2-34
12.1.1 WALK AROUND CHECK .......................................................2-34
12.1.2 CHECK BEFORE STARTING ....................................................2-37
12.1.3 ADJUSTMENT BEFORE OPERATION ............................................2-42
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE ..........................2-45
12.2 STARTING ENGINE ...............................................................2-47
12.2.1 COLD WEATHER STARTING ...................................................2-48
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE ...............................2-49
12.4 MOVING MACHINE ...............................................................2-50
12.5 CHANGING GEARS ..............................................................2-52
12.6 CHANGING DIRECTION ...........................................................2-52
12.7 TURNING .......................................................................2-53
12.8 STOPPING MACHINE .............................................................2-54
12.9 OPERATION OF WORK EQUIPMENT ................................................2-55
12.9.1 STANDARD WORK EQUIPMENT CONTROLS .....................................2-55
12.9.2 MONO-LEVER WORK EQUIPMENT CONTROLS ...................................2-57
12.10 WORK POSSIBLE USING WHEEL LOADER...........................................2-58
12.10.1 DIGGING OPERATIONS ........................................................2-58
12.10.2 LEVELING OPERATIONS .......................................................2-61
12.10.3 PUSHING OPERATION ........................................................2-61
12.10.4 LOAD AND CARRY OPERATIONS ...............................................2-61
12.10.5 LOADING OPERATIONS .......................................................2-62
12.11 PRECAUTIONS FOR OPERATION ..................................................2-63
12.11.1 PERMISSIBLE WATER DEPTH ..................................................2-63
12.11.2 IF WHEEL BRAKE DOES NOT WORK ............................................2-63
12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES ............................2-63
12.11.4 PRECAUTIONS WHEN DRIVING MACHINE .......................................2-64
12.12 ADJUSTING WORK EQUIPMENT POSTURE ..........................................2-65
12.12.1 ADJUSTING BOOM KICKOUT ...................................................2-65
12.12.2 ADJUSTING BUCKET POSITIONER ..............................................2-66
12.12.3 BUCKET LEVEL INDICATOR ....................................................2-66
12.13 PARKING MACHINE ..............................................................2-67
12.14 CHECKS AFTER COMPLETION OF OPERATION ......................................2-68
12.15 STOPPING ENGINE ...............................................................2-68
12.16 CHECK AFTER STOPPING ENGINE .................................................2-69
12.17 LOCKING .......................................................................2-69
12.18 HANDLING THE TIRES ............................................................2-70
12.18.1 PRECAUTIONS WHEN HANDLING TIRES .........................................2-70
12.18.2 TIRE PRESSURE .............................................................2-70
13. TRANSPORTATION .....................................................................2-72
13.1 LOADING AND UNLOADING .......................................................2-72
13.2 PRECAUTIONS FOR LOADING .....................................................2-73
13.3 PRECAUTIONS FOR TRANSPORTATION ............................................2-73
13.4 LIFTING MACHINE ................................................................2-73
13.4.1 LOCATION FOR LIFTING POSITION DECALS......................................2-74
13.4.2 WEIGHT TABLE ..............................................................2-74
13.4.3 LIFTING PROCEDURE .........................................................2-75
14. COLD WEATHER OPERATION ............................................................2-76
14.1 PRECAUTIONS FOR LOW TEMPERATURE ..........................................2-76
14.1.1 FUEL AND LUBRICANTS .......................................................2-76
14.1.2 COOLANT ...................................................................2-76
14.1.3 BATTERY ....................................................................2-76
14.2 PRECAUTIONS AFTER COMPLETION OF WORK ..................................2-77
14.3 AFTER COLD WEATHER .......................................................2-77
15. LONG TERM STORAGE ..................................................................2-78
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