Page 1 WHEEL LOADER SERIAL NUMBERS WA320-3MC - A31001 and up 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 add improvements at any time without incurring any obligation to install such changes on products sold previously.
Page 2 PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SERVICE MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIGN LANGUAGES.
Page 3 REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM Komatsu America International Company AND RETURN TO 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME PURCHASE ORDER NO.
Page 4 INTRODUCTION WA320-3MC...
Page 5 Continuing improvements in the design of this mach ine 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.
Page 6 If you are unsure about the safety of some procedures, contact your local distributor or Komatsu Americ a International Company.
Page 7 If the machine is used for a purpose that is not listed in thi s manua l, Komatsu America International Company cannot bear any responsibility for safety. All consideration o f safety in such operations is the responsibility of the user.
Page 8 INTRODUCTION LOCATION OF PLATES, TABLE FOR SERIAL NUMBER AN D DISTRIBUTOR 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 center of the front frame on the right hand side of the machine.
Page 9 INTRODUCTION TABLE OF CONTENTS 1. FOREWORD ................0 -2 2.
Page 10 INTRODUCTION 12.1.2 CHECK BEFORE STARTING ........... .2-37 12.1.3 ADJUSTMENT BEFORE OPERATION .
Page 11 INTRODUCTION 16.2 TOWING THE MACHINE ............2-80 16.2.1 WITH THE ENGINE RUNNING .
Page 12 INTRODUCTION 24.2.5 CLEAN THE RADIATOR FINS ...........3-35 24.2.6 REPLACE THE BOLT-ON CUTTING EDGES .
Page 13 INTRODUCTION 24.9.8 CLEAN PPC CIRCUIT STRAINER ..........3-73 24.9.9 CHECK ACCUMULATOR GAS PRESSURE .
Page 14 SAFETY WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equipment and attachments. WA320-3MC...
Page 15 Any modification made without authorization from Komatsu America International Company can create hazards. Before making a modification, consult your local distributor. Komatsu America International Company will not be responsible for any injury or damage caused by any unauthorized modification. WA320-3MC...
Page 16 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothes because they are flammable. Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine.
Page 17 WARNING: For reasons of safety, always follow these safety precautions. SAFETY MOUNTING AND DISMOUNTING Climbing on the machine improperly can cause injury. NEVER jump on or off the machine. NEVER get on or off a moving machine. When mounting or dismounting, always face the machine and use the handrails and steps. Do not use the machine's controls or hoses as supports when climbing on or off the machine.
Page 18 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES Engine coolant, engine oil, and hydraulic oil can reach high temperatures, and are under pressure during operation. Attempting to remove the cap, drain the oil or water, or replace the filters may lead to serious burns.
Page 19 When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this manual. Do not use attachments that are not authorized by your distributor or Komatsu America International Company. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
Page 20 Keep flames and heat away from the accumulator. Do not weld anything (such as bosses) to the accumulator. Gas must be released from an accumulator before it can be discarded; consult your Komatsu America International Distributor. VENTILATION FOR ENCLOSED AREAS Be sure to provide adequate ventilation to prevent gas poisoning.
Page 21 WARNING: For reasons of safety, always follow these safety precautions. SAFETY PRECAUTIONS DURING OPERATION BEFORE STARTING ENGINE CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the work shift. Failure to carry out the checks may lead to serious injury or damage. Completely remove all wood chips, leaves, grass, paper and other flammable materials accumulated in the engine compartment and near the battery.
Page 22 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY OPERATING MACHINE WHEN STARTING ENGINE Walk around your machine again just before mounting it, and check for people and objects that might be in the way. Never start the engine if a warning tag has been attached to a control lever (1). When starting the engine, sound the horn to alert nearby personnel.
Page 23 WARNING: For reasons of safety, always follow these safety precautions. SAFETY PRECAUTIONS WHEN STARTING TO MOVE Before starting to move, check again that there is no one in the surrounding area and that there are no obstacles. When starting, sound the horn to alert nearby personnel. Always operate the machine only when seated in the operator’...
Page 24 The tires can overheat and develop excess pressure if subjected to sustained high speed use, for which they were not designed. Tires then may fail, causing loss of control. If you must travel continuously consult Komatsu America International, or your distributor. 1-11...
Page 25 WARNING: For reasons of safety, always follow these safety precautions. SAFETY TRAVELING ON SLOPES Traveling on a slope can allow the machine to tip over or slip to the side. When traveling on slopes, keep the bucket approximately 20 - 30 cm (8-12 in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine stop.
Page 26 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY PRECAUTIONS WHEN OPERATING Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when dropping soil over a cliff, dump one pile, then use the next pile to push the first pile. The load suddenly becomes lighter when a load is pushed over a cliff or when the machine reaches the top of a slope.
Page 27 WARNING: For reasons of safety, always follow these safety precautions. SAFETY DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Going close to high-voltage cables can cause electrical shock. Always maintain the safe distance given below between the machine and the electric cable. The following actions are effective in preventing accidents: 1) Wear shoes with rubber or leather soles.
Page 28 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY OPERATE CAREFULLY ON SNOW When working on snow or icy roads, even a slight slope may cause the machine to slip to the side, so always travel at low speed and avoid sudden starting, stopping, or turning. After a heavy snowfall, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen, so always carry out snow-clearing operations carefully.
Page 29 WARNING: For reasons of safety, always follow these safety precautions. SAFETY PARKING THE MACHINE Park on level ground where danger of falling rocks, flooding and/or landslides is minimal. If the machine must be parked on a slope, block the wheels to prevent the machine from moving. Then dig the work equipment into the ground.
Page 30 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY PRECAUTIONS IN COLD AREAS After completing operations, remove all water, snow or mud from the wiring harness connectors and/or sensors. Cover these parts. If the water freezes, it will cause malfunctions when the machine is used, which may lead to accidents. Warm up the machine thoroughly.
Page 31 Before passing over bridges or structures on private land, first check that the structures will support the mass of the machine. When traveling on public roads, check with the relevant authorities for instructions. The machine can be dismantled for transportation; consult your Komatsu distributor for assistance. 1-18...
Page 32 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. Battery acid could cause blindness if splashed into the eyes.
Page 33 WARNING: For reasons of safety, always follow these safety precautions. SAFETY CHARGING BATTERY The battery can explode if handled incorrectly during charging. Be sure to heed the following and check safety information supplied by the battery charger manufacturer. Remove the battery caps to disperse hydrogen gas and charge in well-ventilated area. Set the voltage of the charge to match the voltage of the battery to be charged.
Page 34 Towing incorrectly may lead to serious personal injury or damage. Make sure all workers involved with the towing agree on signals before starting. If the problem machine’ s engine will not start or has a failure in its brake system, contact your Komatsu distributor for repairs.
Page 35 PRECAUTIONS FOR MAINTENANCE BEFORE CARRYING OUT MAINTENANCE NOTIFICATION OF FAILURE Carrying out maintenance not described in the Komatsu operation and maintenance manual my lead to unexpected failures. Contact your Komatsu distributor for repairs. WARNING TAG If others start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury or death.
Page 36 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY CLEAN BEFORE INSPECTION AND MAINTENANCE Clean the machine before inspection and maintenance so that Procedures can be carried out safely without entry by dirt into the machine. Problem areas are less likely to be obscured by mud and debris.
Page 37 WARNING: For reasons of safety, always follow these safety precautions. SAFETY RADIATOR COOLANT LEVEL When inspecting the radiator coolant level, stop the engine and allow the temperature to subside. Check the coolant level in the sub-tank. Under normal conditions, do not open the radiator cap. If there is no sub-tank, or if the radiator must be removed: Wait for the radiator temperature to go down before checking the coolant level.
Page 38 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Always stop the machine on firm flat ground and stop the engine before carrying out inspection and maintenance. If it is necessary to run the engine when carrying out maintenance, such as when cleaning the inside of the radiator, place the safety lock lever in the LOCK position and carry out the operation with two workers.
Page 39 Replace or repair any such components if any defect is found, even though they have not reached the time specified. Special skills and/or equipment may be required, so contact your Komatsu distributor. Replacement of safety critical components CRITICAL PARTS” on page 3-22.
Page 40 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY DURING MAINTENANCE PERSONNEL Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and/or using a sledge-hammer. ATTACHMENTS Place attachments that have been removed from the machine in a safe place so that they do not fall.
Page 41 WARNING: For reasons of safety, always follow these safety precautions. SAFETY KEEP THE MACHINE CLEAN Spilled oil or grease, or scattered tools or broken pieces are dangerous because they may cause you to slip or trip. Always keep your machine clean and tidy. If water gets into the electrical system, there is danger that the machine may not move or may move unexpectedly.
Page 42 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY HANDLING HIGH-PRESSURE HOSES Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or hoses. They may burst during use. Always repair any loose or broken fuel hoses or oil hoses.
Page 43 WARNING: For reasons of safety, always follow these safety precautions. SAFETY ROTATING FAN AND BELT Keep away from rotating parts and be careful not to let anything get caught in them. If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying, so never touch any rotating parts.
Page 44 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY WASTE MATERIALS Never dump waste oil in a sewer system, rivers, etc. Always put oil drained from your machine in containers. Never drain oil directly on the ground. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and others.
Page 45 WARNING: For reasons of safety, always follow these safety precautions. SAFETY STORING TIRES AFTER REMOVAL As a basic rule, store the tire in a warehouse which unauthorized persons cannot enter. If the tires are stored outside, always erect a fence around the tires and put up a "No Entry" and other warning signs that even children can understand.
Page 46 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY 1. Precautions before starting. 3. Precautions when traveling in reverse. 2. Precautions for safety lock lever. 4. Precautions for parking brake. Part number 419-93-A1410 includes safety labels 1-3; part number 419-93-A1421 identifies safety label 4. 1-33 WA320-3MC...
Page 47 WARNING: For reasons of safety, always follow these safety precautions. SAFETY 5. Do not enter. 7. Precautions for high temperature coolant. 8. Precautions when oil is at high temperature. 6. Precautions for safety bar. 9. Precautions when handling battery cable. Part number 421-93-21311 includes safety labels 5-9.
Page 48 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY 10. Precautions when using booster cables (419-93- AZ130). 11. High pressure warning. 12. Do not climb on fender. 13. Do not go under work equipment. 1-35 WA320-3MC...
Page 49 WARNING: For reasons of safety, always follow these safety precautions. SAFETY 14. Do not open when engine is running. 15. Do not come near machine. 16. Precautions for back-up alarm (417-931-A180). POSITIONS FOR ATTACHING SAFETY LABELS Keep these labels clean. If they are lost or damaged, replace with a new label. Safety labels may be available i n languages besides English.
Page 50 WARNING: Failure follow these safety precautions may lead to a serious accident. SAFETY 1-37 WA320-3MC...
Page 51 OPERATION WA320-3MC...
Page 52 OPERATION GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this manual, they refer to the directions shown by the arrows in the diagram below. WA320-3MC...
Page 53 OPERATION 10.2 GENERAL VIEW OF CONTROLS AND GAUGES WA320-3MC...
Page 54 OPERATION EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating th e equipment and the meanings of the displays. 11.1 MACHINE MONITORS The machine monitor system consists of the main monitor (in front of the operator's seat) and the maintenance monitor...
Page 55 OPERATION Meter Display Portion (A, C, D) (11.1.2) These consists of meters (speedometer, fuel gauge, engine water temperature gauge, torque converter oil temperature gauge, service meter, transmission shift indicator) and the pilot lamps (turn signal indicator, head lamp Hi beam , preheating, front working lamp, rear working lamp, transmission cut-off, parking brake).
Page 56 OPERATION 11.1.1 WARNING DISPLAYS CENTRAL CHECK LAMP (CHECK) WARNING If this monitor flashes, stop the machine for inspection and/or repairs as soon as possible. If any abnormality is found in the CHECK items before starting the engine (engine oil level, engine water level ), the monitor lamp for the abnormal location will flash and the central CHECK lamp will also flash.
Page 57 OPERATION If there is any abnormality in the battery charging system when the engine is running, the battery charge cau tion pilot lamp will flash and the central CHECK lamp will also flash at the same time. If the lamps flash, check the charging circuit. 2.
Page 58 OPERATION 4. ENGINE OIL LEVEL CAUTION PILOT LAMP This warns the operator that the level of oil in the engine oil pan has dropped. When carrying out checks before starting: If the oil l e vel in the engine oil pan is low, the caution pilot lamp and central CHECK lamp will flash.
Page 59 OPERATION 6. ENGINE OIL PRESSURE CAUTION PILOT LAMP This warns the operator that the engine lubricating oil pressure has dropped below a preset level. If it flashes, stop the engine. Damage can occur if the engine is run with insufficient oil pressure. Check that oil level is correct. However, diagnosis of other oil pressure problems may require special tools and trained personnel.
Page 60 OPERATION 11.1.2 METER DISPLAY PORTION PILOT DISPLAY When the starting switch is ON, the pilot display lights when display items are functioning. 1. PARKING BRAKE PILOT LAMP This lamp lights up when the parking brake is applied. 2. TRANSMISSION AUTO SHIFT MANUAL SELECTOR PILOT LAMP When manual transmission is selected, this pilot lamp glows.
Page 61 OPERATION 3. FRONT WORKING LAMP PILOT LAMP This lamp lights up when the front working lamp is switched ON. 4. REAR WORKING LAMP PILOT LAMP This lamp lights up when the rear working lamp is switched ON. 5. TRANSMISSION CUT-OFF PILOT LAMP This lamp lights up when the transmission cut-off switch is turned to If the monitor lamp is ON and the left brake pedal is depressed, the transmission will be returned to neutral.
Page 62 OPERATION 8. FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. E: Tank is EMPTY F: Tank is FULL The lamp should light up in the green range during operation. If it enters the red ran ge during operation, it means that there is less than 44 liters (11.6 US gal.) of fuel left, so check and add fuel.
Page 63 OPERATION 12. SPEEDOMETER This meter indicates the travel speed of the machine. 13. TRANSMISSION SHIFT INDICATOR This indicates the present speed range of the transmission. When the directional lever is at N position, N is displayed on th e indicator. When the directi o nal lever is at the F or R position, the shift position of the speed lever is displayed as numeral.
Page 64 OPERATION 11.2 SWITCHES 1. STARTING SWITCH This switch is used to start or stop the engine. OFF position The key can be inserted and removed at this position. When the key is turned to this position, the electric circuit is turned off and th e engine stops.
Page 65 OPERATION 2. TRANSMISSION CUT-OFF SWITCH WARNING If the machine must be started on a slope, always turn the transmission cut-off switch to OFF and depress the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine moving slowly.
Page 66 OPERATION 5. TRANSMISSION SELECTOR SWITCH This switch when depressed once selects the “ on” position, o r manual transmission mode. The lamp is lit. Depressing the switch again selects the “ off” position, which is Auto-Shift transmissio n mode, and the lamp is off. Normal operation should be in the “...
Page 67 OPERATION 7. HORN BUTTON When the button in t h e center of the steering wheel is pressed, the horn will sound. 8. HAZARD LAMP SWITCH WARNING Use the hazard lamps only in emergencies. Using the hazard lamps when traveling will cause problems for other machines.
Page 68 OPERATION 10. HOLD SWITCH The Hold switch, located on the lift lever, will maintain th e transmission gear. When this switch is depressed, transmissio n indicator light on the main monitor panel will light. Depressing thi s switch again will release the transmission hold function and th e indicator light will go off.
Page 69 OPERATION 14. ROOM LAMP SWITCH REMARKS: The room lamp can light even if the main switch is OFF. To avoid draining the vehicle battery, turn the switch to position 1 or OF F before leaving the operator's compartment. When operating wit h the cab door fully open, set the switch to position 1 (OFF).
Page 70 OPERATION 16. REAR WINDOW DEFROSTER Switch (1) energizes a timing circuit to power the window defroster. Place the defroster switch to ON and the system will operat e approximately 10 minutes, long enough in most cases to clear the window. 17.
Page 71 OPERATION 11.3 CONTROL LEVERS, PEDALS 1. SPEED CONTROL LEVER MANUAL SHIFT This lever controls the travel speed of the machine. This machine has a 4-FORWARD, 4-REVERSE speed transmission. Place the speed control lever in a suitable position to obtain th e desired speed range.
Page 72 OPERATION The Auto Shift transmission can change from second to fourth gear to cope with operating conditions. (1) Position First gear (2) Position Second gear (3) Position Third gear (4) Position Fourth gear This chart il l ustrates the Auto Shift gear ranges available according to the shift lever position.
Page 73 OPERATION 2. DIRECTIONAL LEVER This lever is used to change the direction of travel of the machine. The engine cannot be started if the directional lever is not at N (neutral). Position (1): Forward Position (N): Neutral Position (2): Reverse REMARKS: The length of the lever can be adjusted to 3 stages (positions (A) , (B) or (C)).
Page 74 OPERATION 5. BUCKET CONTROL LEVER This lever operates the bucket. (1) TILT ( When the bucket control lever is pulled further from the TILT position, the lever i s stopped in this position until the bucke t reaches the preset position of the positioner, and the lever returns to the HOLD position.
Page 75 OPERATION 7. BRAKE PEDALS WARNING When traveling downhill, use the engine as a brake, and always use the right brake pedal. Do not use the brake pedals repeatedly unless necessary. Do not put your foot on this pedal unless necessary. Right brake pedal The right brake pedal operates the wheel brakes, and is used fo r normal braking.
Page 76 OPERATION 11.4 STEERING COLUMN TILT LEVER WARNING Stop the machine before adjusting the angle of the steering wheel. This lever allows the steering column to be tilted forward or backward. Pull the lever up and move the steering wheel to the desire d position.
Page 77 OPERATION 11.5 CAP WITH LOCK The fuel tank filler port and the hydraulic tank filler port are equipped with locks. Use the starter key to open and close the cap as follows. 11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK TO OPEN THE CAP (For the fuel tank filler port) 1.
Page 78 OPERATION TO OPEN THE CAP (For the hydraulic tank filler port) 1. Insert the key into the cap as far as it will go. If the key is turned before it is inserted all the way in, it could break. 2.
Page 79 OPERATION 11.6 SAFETY BAR WARNING Always use the safety bar for maintenance or when transporting the machine. The safety bar is used dur ing maintenance or when transporting the machine. It locks the front and rear frames, and prevents the front and rear frames from pivoting.
Page 80 OPERATION 11.8 GREASE PUMP The grease pump is stored inside the battery box at the rear of the machine. After using it wipe off all grease stuck to the outside of the pump and then store it in the box. It can be stored in either the left or right battery box.
Page 81 OPERATION 11.10 FUSE NOTE: Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If a fuse becomes corroded, or white powder can be seen, or a fuse is loose in the fuse holder, replace the fuse.
Page 82 OPERATION Fuse box II Fuse Name of circuit capacity Front working lamp Rear working lamp Air conditioner Air conditioner Wiper, washer Auto shift Cigarette lighter, radio Rotating lamp Fuel shut off solenoid Spare Spare Spare Spare Air suspension seat Defroster 11.11 SLOW-BLOW FUSE If the power does not come on when the starting switch is turne d ON, check the slow-blow fuse.
Page 83 OPERATION 11.12 STORAGE FOR THIS MANUAL Keep this manual in its convenient storage pocket on the rear of the operator’ s seat. 11.13 ELECTRIC POWER (with ROPS CAB) Electric current (up to 7A (168 W)) is av ailable at the cigarette lighter receptacle.
Page 84 OPERATION OPERATION 12.1 CHECKS BEFORE STARTING 12.1.1 WALK AROUND CHECK WARNING Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or turbocharger, may cause fire. Check carefully, and if any abnormality is found, repair it or contact your distributor for assistance.
Page 85 OPERATION 2. Remove dirt and dust from around engine, battery, radiator Check for dirt or dust accumulated around the engine or radiator. Check also if there is any flammable material (dead leaves, twigs, grass, etc.) accumulated around the battery or high temperature engine parts, such as the muffler or turbocharger.
Page 86 Check for any loose or damaged bolts. If any loose bolts are found tighten them to 927 ± 103 N If any bolts are damaged, replace them with genuine Komatsu bolts. 13. Clean cab window Clean the cab windows to ensure good visibility when operating the machine.
Page 87 OPERATION 12.1.2 CHECK BEFORE STARTING Always carry out the items in this section before starting the engine each day. CHECK MONITOR PANEL 1. Turn the starting switch to ON. 2. Check that all the monitor lamps, the gauges and the warning lamp light up for about 3 seconds and the alarm buzzer sounds for about 1 second.
Page 88 OPERATION INSPECTION OF TIRES WARNING Worn or damaged tires may fail and cause death or serious injury. Replace tires that are not in usable condition: Wear Tires with tread groove less than 15% of that of a new tire. Tires with extremely uneven wear or stepped-type wear. Damage Tires with damage that has reached the cords, or with cracks in the rubber.
Page 89 OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the engine side cover at the right rear side of th e machine. 2. Remove dipstick (G) and wipe the oil off with a clean cloth. 3. Insert dipstick (G) fully in the guide tube, then take it ou t again.
Page 90 OPERATION CHECK ELECTRICAL WIRING WARNING If fuses are frequently blown or if there are traces of a short circuit in the wiring, locate the cause and carry out repair. Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause fire, so always remove such material.
Page 91 OPERATION CHECK EFFECT OF PARKING BRAKE WARNING Even if the parking brake switch is turned ON, for safety precaution keep the brake pedal depressed until the parking brake pilot lamp lights up. Measurement conditions Tire inflation pressure: Specified pressure Road surface: Dry paved surface with 1/5 (11 Machine: Operating condition...
Page 92 OPERATION 12.1.3 ADJUSTMENT BEFORE OPERATION OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine before adjusting seat. Adjust the seat before starting operations or when changine operators. Check that you can depress the brake pedal fully with your back against the seat backrest. (1) Forward-backward adjustment Pull lever (1) up, and move the seat to the desired position, then release the lever to lock in place.
Page 93 OPERATION AIR RIDE SUSPENSION SEAT The optional Air Ride Seat adds to the seat a suspension syste m with a built-in air compressor for added comfort over uneven terrain. Controls resemble those of the standard seat with a few exceptions. (1) Forward-backward adjustment Pull lever (1) to release the seat and then slide the seat to a position that provides comfort and accessibility to controls.
Page 94 OPERATION ADJUST SEAT BELT WARNING Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting of the belt. If the belt is worn or damaged, replace it. Always fasten the seat belt before operations. Always install a seat belt on machines equipped with ROPS.
Page 95 OPERATION 12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING If the control levers are touched by accident, the work equipment could move suddenly. When leaving the operators compartment, always set the safety lever securely to the LOCK position. Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery or on the starting motor and alternator.
Page 96 OPERATION 4. Insert the key in starting switch (5), turn the key to the O N position, and check that the pilot lamp lights up. 2-46 WA320-3MC...
Page 97 OPERATION 12.2 STARTING ENGINE WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTE: Do not operate the starting motor continuously for more than 20 seconds. If the engine will not start, wait for at least two minutes before trying to start the engine again.
Page 98 OPERATION 12.2.1 COLD WEATHER STARTING WARNING Use the ether start switch only when starting engine. Keep sparks and flames away from the ether cylinder. Never throw a cylinder in fire. Never drill a hole in the cylinder. Do not store a cylinder where temperature rises over 40 (104 F).
Page 99 OPERATION 12.3 OPERATIONS CHECKS AFTER STARTING ENGINE After starting the engine, do not immediately start work. Carry out the following operations and checks. NOTE: Do not suddenly accelerate the engine before the warming-up operation is completed. Do not run the engine at low idle or high idle continuously for more than 20 minutes.
Page 100 OPERATION 12.4 MOVING MACHINE WARNING When moving the machine, check that the area around the machine is safe, then sound the horn before starting. Do not allow people near the machine. The engine cover partially obscures view to the rear, so be particularly careful when traveling in reverse.
Page 101 OPERATION 3. Operate lift arm control lever (6) to set the work equipment to the travel posture shown in the diagram. 4. Depress right brake pedal (8) and turn parking switch (9) to the OFF (RELEASE) position to release the parking brake. Keep right brake pedal (8) depressed.
Page 102 OPERATION 12.5 CHANGING GEARS WARNING When traveling at high speed, do not change the gear speed suddenly. When shifting gears, use the brake to reduce the travel speed, then shift gears. Shift gears as follows. Move speed control lever (1) to the desired position. Only 1st or 2nd speeds are use d for digging and loading operations, so actuate speed control lever stopper.
Page 103 OPERATION AUTO-SHIFT TRANSMISSION An alarm sounds when changing direction with the machine moving. Depress the brake pedal to reduce travel speed before changing direction. The warning alarm will sound if engine and travel speed are a s shown in “ Area II” on the ch art. The alarm sounds for three seconds if the engine speed and tra vel speed are as shown in “...
Page 104 OPERATION 12.8 STOPPING MACHINE WARNING Avoid stopping suddenly. Allow ample room when stopping. Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 105 OPERATION 3. Turn parking brake switch (4) to ON to apply the parkin g brake. REMARKS: When the parking brake is appli e d, the transmission is automatically returned to neutral. 12.9 OPERATION OF WORK EQUIPMENT 12.9.1 STANDARD WORK EQUIPMENT CONTROLS Lift arm control lever (1) and bucket control lever (2) can be used to operate the lift arm and bucket as follows.
Page 106 OPERATION BUCKET OPERATION (LEVER (2)) (1) TILT ( (2) HOLD ( The bucket is kept in the same position. (3) DUMP ( When the bucket control lever is pulled further from the til t position, the lever is stopped in this position until the bucke t reaches the preset position of the positioner, and the lever i s returned to the hold position.
Page 107 OPERATION 12.9.2 MONO LEVER WORK EQUIPMENT CONTROLS With the optional mono lever controls, work equipment lever (1) can be used to operate the lift arm and bucket as follows. LIFT ARM OPERATION (LEVER (1)) (1) RAISE ( (2) HOLD ( The lift arm is kept in the same position.
Page 108 OPERATION 12.10 WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is pos s ible to further increase the range of applications by using various attachments. 12.10.1 DIGGING OPERATIONS WARNING Always set the machine facing directly to the front when carrying out digging or scooping operations.
Page 109 OPERATION 5. Check that there is enough material loaded into the bucket, then operate the bucket control lever to tilt the bucket and load the bucket fully. REMARKS: If the bucket edge is moved up and down while pushing in th e bucket and digging, the front wheels could raise up and allow th e tires to slip.
Page 110 OPERATION When digging and loading on level ground, set the bucket edg e facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalance load. This operation should be carried out in first gear. 1.
Page 111 OPERATION 12.10.2 LEVELING OPERATIONS NOTE: Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20 degrees. 1.
Page 112 OPERATION 12.10.5 LOADING OPERATIONS Select the method of operation which will give the minimum amount of turning and travel and provide the most efficient method for th e job site. WARNING Always keep the working area flat. Turning or applying the brake suddenly when traveling with a raised load can lead to loss of control.
Page 113 OPERATION 12.11 PRECAUTIONS FOR OPERATION 12.11.1 PERMISSIBLE WATER DEPTH When working in water or on swampy ground, do not let the water come above the bottom of the axle housing. After finishing the operation, wash and check the lubricating points. 12.11.2 IF WHEEL BRAKE DOES NOT WORK If the machine is not stopped by depre ssing the brake pedal, use the parking brake to stop the machine.
Page 114 OPERATION 12.11.4 PRECAUTIONS WHEN DRIVING MACHINE Traveling at high speed for a long distance causes the tires t o become extremely hot, accelerating wear. Avoid high speeds a s much as possible. If the machine must be driven for a long distance, take the following precautions.
Page 115 OPERATION 12.12 ADJUSTING WORK EQUIPMENT POSTURE WARNING Stop the machine on flat ground and put blocks in front and behind the wheels. Apply the parking brake. Secure the front and rear frames with safety bar. Never go under the work equipment when the arm is raised. The boom kickout allows setting the bucket to automatically stop at the desired lifting height (lift arm higher than horizontal) and th e bucket positioner sets the bucket to s top automatically at the desired...
Page 116 OPERATION 12.12.2 ADJUSTING BUCKET POSITIONER 1. Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the bucket control lever a t HOLD, stop the engine and adjust as follows. 2. Loosen two bolts (1) and adjust mounting bracket (4) of the proximity switch so that the re ar tip of angle (2) is in line with the center of the sensing surface of the proximity switch (3).
Page 117 OPERATION 12.13 PARKING MACHINE WARNING Avoid stopping suddenly. Allow ample room when stopping. Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 118 OPERATION 4. Operate lift arm control lever (5) to lower the bucket to the ground. 5. Lock lift arm control lever (5) and bucket control lever (6) with safety lock (7). 12.14 CHECKS AFTER COMPLETION OPERATION Check the engine water temperature, engine oil pressure, torqu e converter oil temperature, and fuel level with the meter and lamps.
Page 119 OPERATION leaks. If there are any leaks or abnormalities found, carry out repairs. 2. Fill the fuel tank. 3. Remove any waste paper or leaves from inside the engine compartment. They could cause a fire. 4. Remove any mud from the undercarriage. 12.17 LOCKING Always lock the following places.
Page 120 OPERATION 12.18 HANDLING THE TIRES 12.18.1 PRECAUTIONS WHEN HANDLING TIRES Replace tires that show one or more of these defects. Bead wire is broken or bent, or the tire is greatly deformed. Wear is excessive and the carcass ply (excluding breaker) is exposed for more than 1/4 of the circumference.
Page 121 OPERATION If the deflection of the tire is excessive, raise the inflation pressur e within the limits given in this table to give a suitable deflection (see deflection ratio). Inflation pressure (kg/cm²) Soft ground When Tire size (sandy Normal road shipped Ply rating (pattern)
Page 122 OPERATION TRANSPORTATION When transporting the machine, observe all the related laws and regulations, and always assure safety. 13.1 LOADING, UNLOADING WORK WARNING Make sure the ramp has sufficient width, length and thickness to enable the machine to be safety loaded and unloaded.
Page 123 OPERATION 13.2 PRECAUTIONS FOR LOADING After loading the machine, secure it in place as follows. 1. Lower the work equipment slowly. 2. Apply the safety lock to lock all the control levers. 3. Turn the starting switch to the OFF position and stop th e engine.
Page 124 OPERATION 13.3.1 LOCATION FOR LIFTING POSITION DECALS Operating Front wheel Rear wheel Center of gravity (from weight load load front axle) 14120 kg 5700 kg 8420 kg 1806 mm (31135 lb) (12569 lb) (18566 lb) (5 ft, 11 in.) 2-74 WA320-3MC...
Page 125 OPERATION 13.3.3 LIFTING PROCEDURE NOTE: The lifting procedure applies only to machines with lifting lugs. Stop the machine on a horizontal surface. 1. Start the engine, make sure the machine is horizontal, and then move the work equipment to the travel position. See “12-4 MOVING MACHINE”...
Page 126 OPERATION COLD WEATHER OPERATION 14.1 PRECAUTIONS FOR LOW TEMPERATURE Extremely low temperatures may make the engine difficult to start, and cause the coolant to freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Use fuel and oil with low viscosity for all components. For details , see "20.
Page 127 OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK Protect the machine from mud and water, which can freez e overnight, preventing movement the following morning. Observe the following precautions. Mud and water in and on the machine should be completely removed. Park the machine on hard, dry ground.
Page 128 OPERATION LONG TERM STORAGE 15.1 BEFORE STORAGE Prepare the machine for long term storage as follows. Wash and dry every part and move the machine into a dry building. If the machine must be left outdoors, park on well drained concrete and cover with canvas, etc. Completely fill the fuel tank, lubricate, and change the oi l before storage.
Page 129 OPERATION TROUBLESHOOTING 16.1 WHEN MACHINE RUNS OUT OF FUEL WARNING The engine will start, so check carefully that the area around the engine is safe before cranking the engine. If the machine has run out of fuel, add fuel then bleed the air from the fuel system before starting the engine.
Page 130 OPERATION 16.2 TOWING THE MACHINE WARNING Improper towing could lead to serious injury or damage. If the brakes cannot be used, be extremely careful when towing. NOTE: Limit towing to emergencies -- moving the machine to a place where inspection and maintenance can be carried out.
Page 131 OPERATION The towing machine should normally be of the same class as the machine being towed. Check that the towing mac hine has ample braking power, weight, and rimpull to allow it to control both machines while on a slope. When towing the machine downhill, use a larger machine for towing to provide ample rimpull and braking power, or connect another machine to the rear of the machine being...
Page 132 OPERATION 16.2.3 RELEASING PARKING BRAKE WARNING Stop the machine on a flat surface when releasing the parking brake, and check that the surroundings are safe. In emergencies or when the parking brake must be released on a hill, block the tires carefully before releasing the brake.
Page 133 OPERATION 16.2.4 EMERGENCY TRAVEL OPERATION The normal gear shift operation is carried out by electric signals. If there should be a failure in the electrical system and the machine does not move, it is possible to move the machine by using th e following procedure.
Page 134 OPERATION 16.3 IF BATTERY IS DISCHARGED WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. Before starting the engine, use a damp cloth to wipe dust and debris from the top surface of the battery. The battery generates hydrogen gas, so there is danger of explosion.
Page 135 OPERATION 16.3.2 PRECAUTION FOR CHARGING BATTERY CHARGING BATTERY ON MACHINE Before charging, di s connect the cable from the negative (-) terminal of the battery. Otherwise, an unusually hig h voltage could damage the alternator. While charging the battery, remove all battery plugs fo r satisfactory ventilation.
Page 136 OPERATION 16.3.3 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: Precautions when connecting and disconnecting booster cable. WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals together. When starting the engine with a booster cable, always wear safety glasses.
Page 137 OPERATION CONNECTING THE BOOSTER CABLES Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Make sure that the starti n g switches of the normal machine and problem machine are both at the OFF position.
Page 138 OPERATION 16.4 OTHER TROUBLE 16.4.1 ELECTRICAL SYSTEM ( ): Always contact your distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even Check, repair loose when the engine runs at high terminals, disconnections)
Page 139 OPERATION 16.4.2 CHASSIS ( ): Always contact your distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your distributor for repairs. Problem Main causes Remedy TRANSMISSION Engine is running but machine Parking brake is applied Release parking brake does not move...
Page 140 OPERATION CHASSIS (continued) Problem Main causes Remedy BRAKE Brake is not applied when Disc has reach wear limit Replace disc) pedal is depressed Defective hydraulic system Lack of oil Add oil to specified level. See “24.5 EVERY 100 HOURS SERVICE” on page Air in brake line 3-46.
Page 141 OPERATION CHASSIS (continued) Problem Main causes Remedy HYDRAULIC SYSTEM Lack of lifting power for Lack of oil Add oil to specified level. See “24.5 bucket EVERY 100 HOURS SERVICE” Bucket takes time to raise on page 3-46. Clogged hydraulic tank filter Replace filter.
Page 142 OPERATION 16.4.3 ENGINE ( ): Always contact your distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your distributor for repairs. Problem Main causes Remedy Engine oil pressure Engine oil pan oil level is low Add oil to specified level, see caution pilot lamp lights (sucking in air)
Page 143 OPERATION CHASSIS continued (16.4.3) Problem Main causes Remedy Exhaust is white or blue Too much oil in oil pan Add oil to specified level. See “12.1.2 CHECK Improper fuel BEFORE STARTING” on page 2-42.”. Change to specified fuel Exhaust gas occasionally turns Clogged air cleaner element Clean or replace, see “24.2 black...
Page 144 MAINTENANCE WA320-3MC...
Page 145 Komatsu genuine replacement parts: Use genuine Komatsu parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use genuine Komatsu oils and grease. Choose oils and grease with proper viscosities specified for ambien t temperature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
Page 146 MAINTENANCE Check for foreign materials in drained oil and on filter: After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign materials. If large quantities of metallic particles or foreign materials are found, consult your distributor. Fuel strainer: If your machine is equipped with a fuel strainer, do not remove it while fueling.
Page 147 MAINTENANCE Dusty work sites: When working at dusty work sites, do as follows: Inspect the air cleaner clogging pilot lamp to see whether the air cleaner is plugged up. Clean the air cleaner at shorter intervals than specified. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently.
Page 148 Fuel (However, ASTM D975 No. 1 is used for the winter season (October to March) Radiator 50/50 Mixture of Komatsu Super Coolant and water 18.1 OUTLINE OF OIL, FUEL, COOLANT 18.1.1 OIL Oil is used in the engine and work equipment under ext r emely severe conditions (high temperature, high pressure), and it deteriorates with use.
Page 149 MAINTENANCE 18.1.2 FUEL The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly. Be extremely careful not to let impurities get in when storing or adding fuel. Always use the fuel specified in the Operation and Maintenance Manual. Fuel may congeal depending on the temperature when it is used (particularly in low temperatures below-15 C To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work.
Page 150 When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your distributor. Do not open packs of spare filters until just before they are to be used. Always use genuine Komatsu filters. FUEL INJECTION PUMP DO NOT ATTEMPT TO ADJUST THE FUEL INJECTION PUMP Unsatisfactory operation of the engine may not be due to the fuel injection pump.
Page 151 Never remove or disassemble any electric components installed in the machine. Never install any electric components other than those specified by Komatsu. Be careful to keep the electric system free of water when washing the machine or when it rains.
Page 152 The wear parts should be changed correctly in order to use the machine economically. For part replacement, genuine Komatsu parts of excellent quality should be used. Find the current part numbers in the Parts Book provided with your equipment and write them in the Part Number column.
Page 153 The responsibility for the quality of the fuel, cool ant and lubricant must remain with the supplier. When in doubt, consult your Komatsu distributor. The specified fuel, coolant and lubricants recommended for this machine are as shown in the following table.
Page 154 MAINTENANCE Other equipment may be necessary when operating the machine at temperatures below -20 consult your Komatsu distributor for your specific needs. When operating the machine at temperatures below -20 distributor. NOTE: For axle oil, use only the recommended oil as follows.
Page 155 The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability. Komatsu Engine Oil or multi-viscosity engine oil meeting American Petroleum Institute (API) performance classification CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
Page 156 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS Komatsu Engine Oil or engine oil meeting American Petroleum Institute (API) performance classification CF-4, CG- 4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
Page 157 MAINTENANCE REMARK Below -12 the fuel filters. For best results use Grade No. 1-D diesel fuel in cold weather. For normal service above -10 number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Page 158 MAINTENANCE 20.6.3 ANTIFREEZE In climates where the temperature is above -34 antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required.
Page 159 MAINTENANCE Percentage of Antifreeze Approximate Freezing Point Specific Gravity at 16 Concentration by Volume (+32 1.000 (+20 1.025 1.040 1.053 (-10 1.062 (-20 1.070 (-30 1.074 (-40 1.080 (-50 1.083 (-60 1.088 (-70 1.092 (-80 1.095 (-90 1.097 (-92 1.098 In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor or supplemental coolant additive (SCA), to protect the engine cooling system.
Page 160 MAINTENANCE Coolant Testing for Conditioner Concentration When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The SCA concentration must not fall below 1.0 unit per 3.8 only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis.
Page 161 MAINTENANCE DCA4 UNIT GUIDE Fleetguard Part No. DCA4 Units DCA4 Coolant Filter WF-2070 WF-2071 WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 WF-2077 DCA4 Liquid DCA60L 4 (1 pt) DCA80L 1760 (55 gal) DCA4 Powder DCA95 DCA4 Precharge and Service Filters System Capacity Precharge Filter Service Filter (See NOTE 1)
Page 162 Cooling System Test Kit The following cooling system test kit may be purchased from your Komatsu America International Company distributor. This Fleetguard® coolant test kit, part number CC-2626 is used to check the concentration of coolant additives in the cooling system.
Page 163 MAINTENANCE STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS 21.1 INTRODUCTION OF NECESSARY TOOLS The following tools are needed when carrying out maintenance. Name of tool Part No. Remarks Wrench set 09000-30006 Applicable width across flats (S - S ) 8 mm - 10 mm 12 mm - 14 mm 13 mm - 17 mm 19 mm - 22 mm...
Page 164 The tightening torque is determined by the width across the flats (b)of the nut and bolt. If it is necessary to replace any nut or bolt, always use a genuine Komatsu part of the same size as the part that was replaced. Thread diameter of bolt...
Page 165 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To ensure safety at all times when operating or driving the machine, the user is responsible for periodic maintenance. In addition, to further improve safety, the user should also replace at regular intervals the parts given in the table.
Page 166 MAINTENANCE SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Replacement interval Qty. Fuel hose (fuel tank - strainer) Fuel return hose (strainer - injection pump) Every 2 years or 4000 hours, whichever comes first Fuel return hose (injection pump - fuel tank) Steering hose (pump - priority valve) Steering hose (priority valve - orbitrol valve) Steering hose (orbitrol valve - steering valve)
Page 167 MAINTENANCE 3-24 WA320-3MC...
Page 168 MAINTENANCE 3-25 WA320-3MC...
Page 169 MAINTENANCE MAINTENANCE SCHEDULE 23.1 SCHEDULED MAINTENANCE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filter cartridge 3-30 Replace transmission oil filter element 3-30 Replace hydraulic tank filter element 3-30 WHEN REQUIRED Check, clean and replace air cleaner element 3-31 Check transmission oil level, add oil 3-33...
Page 170 MAINTENANCE SERVICE ITEM PAGE CHECKS BEFORE STARTING (continued) Check effect of parking brake 2-41 Check effect of wheel brakes 2-41 Check sound of horn and backup alarm 2-41 Check flashing of lamps, check for dirt or damage 2-41 Check engine exhaust color and sound 2-41 Check operation of gauges 2-41...
Page 171 MAINTENANCE SERVICE ITEM PAGE EVERY 250 HOURS SERVICE (continued) 3-52 3-52 3-52 Replace coolant corrosion resistor cartridge 3-53 EVERY 500 HOURS SERVICE Replace fuel filter cartridge 3-54 Replace transmission oil filter element 3-56 Lubricate center drive shaft spline (1 point) 3-60 EVERY 1000 HOURS SERVICE Change oil in transmission case, clean strainer...
Page 172 MAINTENANCE SERVICE ITEM PAGE EVERY 2000 HOURS SERVICE (continued) Check vibration damper 3-77 Replace element in air conditioner recirculation air filter and fresh air filter 3-77 Clean PPC circuit strainer 3-78 Check accumulator gas pressure 3-78 3-29 WA320-3MC...
Page 173 MAINTENANCE SERVICE PROCEDURE 24.1 INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. REPLACE FUEL FILTER CARTRIDGE REPLACE TRANSMISSION OIL FILTER ELEMENT REPLACE HYDRAULIC TANK FILTER ELEMENT For details of the method of replacing or maintaining, see the sections on 500 HOURS and 2000 HOURS SERVICE.
Page 174 MAINTENANCE 24.2 WHEN REQUIRED 24.2.1 CLEAN OR REPLACE AIR CLEANER ELEMENT WARNING Never clean or replace the air cleaner element with the engine running. When using pressurized air to clean the element wear safety glasses or goggles to protect the eyes. Checking If air cleaner clogging caution lamp (1) on the maintenance monitor flashes, clean the air cleaner element.
Page 175 MAINTENANCE Replacing Inner Element 1. First remove the cover and the outer element, and then remove the inner element. 2. To prevent dust from getting in, use a clean cloth or tape to cover the air connector (outlet side). 3. Clean the air cleaner body interior, then remove the cover installed in Step 2.
Page 176 MAINTENANCE 24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL WARNING When checking the oil level, apply the parking brake and lock the front and rear frames with the safety bar and pin. The oil is at a high temperature after the machine has been operated.
Page 177 MAINTENANCE 24.2.3 CHECK AXLE OIL LEVEL, ADD OIL WARNING When checking the oil level, apply the parking brake and lock the front and rear frames with the safety bar and pin. The oil is at a high temperature after the machine has been operated.
Page 178 MAINTENANCE 24.2.4 CLEAN THE AXLE CASE BREATHER WARNING When checking the oil level, apply the parking brake and lock the front and rear frames with the safety bar and pin. Remove all mud and dirt from around the breather with a brush. When cleaning the breather, clean the breather at two places (front and rear).
Page 179 MAINTENANCE 24.2.6 REPLACE THE BOLT-ON CUTTING EDGES WARNING It is extremely dangerous if the work equipment moves when performing this procedure. Set the work equipment in a stable position, turn off the engine, then set the safety lock for the work equipment control lever securely to the LOCK position.
Page 180 MAINTENANCE 24.2.7 REPLACE BUCKET TEETH WARNING It is extremely dangerous if the work equipment moves when performing this procedure. Set the work equipment in a stable position, turn off the engine, then set the safety lock for the work equipment control lever securely to the LOCK position.
Page 181 MAINTENANCE 24.2.8 CHECK AIR CONDITIONER Check twice a year: spring and autumn. Check Levels of Refrigerant (Gas) WARNING The refrigerant in the system can injure eyes or skin. To avoid blindness and/or frostbite, avoid contact with the substance; NEVER loosen any part of the refrigerant circuit. Operate the air conditioner system for 5 to 10 minutes, then touch the high pressure portion and low pressure portion of the compressor (or high pressure hose and low pressure hose joint)
Page 182 MAINTENANCE 24.2.9 CLEAN THE AIR CONDITIONER CONDENSER WARNING Do not wash the condenser with a steam cleaner. Otherwise, the condenser will get hot and could break down If there is mud or dust on the air conditioner condenser, clean it with water.
Page 183 MAINTENANCE 24.2.13 REPLACE SLOW BLOW FUSE NOTE: Always turn the power OFF when replacing the slow blow fuse (turn the starting switch to the OFF position). Always replace the slow blow fuse with a fuse of the same capacity. 1. Turn the starting switch to the OFF position. 2.
Page 184 Select the tires according to the conditions of use and attach- ments of the machine. Use the following table. Since the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires. Check Tire Pressure and Inflating Tires...
Page 185 Check the monitor lamps, the gauges and the warning lamp see “12.1.2 CHECK BEFORE STARTING” on page 2-42. If any monitor lamp does not light up, ask your Komatsu distributor to inspect that monitor lamp. Do not carry out the checks before starting using only the monitor;...
Page 186 MAINTENANCE 24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the engine side cover at the rear right side of the machine. 2. Remove dipstick (1) and wipe the oil off with a cloth. Insert dipstick fully in the oil filler pipe, then take it out again. The oil level should be between the H and L marks on dipstick.
Page 187 When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. 24.3.6 DRAIN WATER FROM FUEL WATER SEPARATOR With the engine shut off, open the drain valve (1).
Page 188 MAINTENANCE 24.3.7 CHECK EFFECT OF PARKING BRAKE WARNING Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed. Measurement Conditions Tire inflation pressure ....Specified pressure Road surface .
Page 189 MAINTENANCE 24.4 EVERY 50 HOURS SERVICE 24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve (1) on the right side of the tank so that the sediment and water will be drained together with fuel. 24.5 EVERY 100 HOURS SERVICE Maintenance for every 50 hours should be carried out at the same time.
Page 190 MAINTENANCE 24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER WARNING When using compressed air, wear safety glasses and other approved protective apparel. If the air conditioner has been used, its air filter element could need cleaning. Before cleaning the elements, turn the air conditioner OFF.
Page 191 MAINTENANCE 24.6 EVERY 250 HOURS SERVICE Maintenance for every 50 and 100 hours should be carried out at the same time. 24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING Before changing the oil, wait, at least 10 minutes for the engine to cool down after running it.
Page 192 MAINTENANCE Fill a new oil filter with engine oil. Then, apply engine oil or a thin coat of grease to the seal. 8. To install filter, bring its seal surface into contact with sealing surface of filter base and then tighten the filter ½ to ¾ turn by hand.
Page 193 MAINTENANCE 24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER 1. Open the filter inspection cover, remove the filter cover, then remove the filter in the direction of the arrow. When removing the filter to the side, put your weight on the seat, and push down.
Page 194 MAINTENANCE 24.6.5 CHECK BATTERY ELECTROLYTE LEVEL WARNING To avoid gas explosions, keep fire and/or sparks away from the battery. Battery electrolyte is acidic and can injure eyes or skin. If itcontacts eyes or skin, flush it away with water, and get medical help imediately.
Page 195 MAINTENANCE 24.6.6 CORROSION RESISTOR WARNING Do not remove the radiator cap from a hot engine. Hot steam will cause serious personal injury. Wait until the coolant temperature is below 50 pressure cap. Remove the coolant system pressure cap and close the shutoff valve before removing the corrosion resistor.
Page 196 MAINTENANCE 24.6.7 LUBRICATING WARNING Set the work equipment in a stable condition, then turn OFF the machine and apply the lock for the work equipment control levers. Apply the parking brake, and lock the front and rear frames with the safety bar and pin. Use a grease pump to pump in grease through the grease fittings marked by the arrows.
Page 197 MAINTENANCE 24.7 EVERY 500 HOURS SERVICE Maintenance for every 50, 100 and 250 hours service should be carried out at the same time. 24.7.1 REPLACE FUEL FILTER CARTRIDGE WARNING Engine temperature remains high immediately after the machine has been operated. Wait for engine to cool down before replacing the filter.
Page 198 MAINTENANCE 6. After replacing the fuel filter cartridge, run the engine at idle for a few minutes. Check for leaks and repair as necessary. 7. Close the engine hood. NOTE: Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically, if the fuel filter is changed in accordance with the instructions.
Page 199 2. Hold case (2) and loosen center bolt (3), then remove case (2). Be sure to use a genuine Komatsu filter element. Replace the filter gasket and O-rings with new parts. Coat the gasket and O-rings with clean engine oil before installing.
Page 200 MAINTENANCE 24.8 EVERY 1000 HOURS SERVICE Maintenance for every 50, 100, 250 and 500 hours should be carried out at the same time. 24.8.1 CHANGE OIL IN TRANSMISSION, CLEAN STRAINER WARNING The oil is at a high temperature immediately after the machine has been operated.
Page 201 MAINTENANCE 24.8.2 CLEAN TRANSMISSION CASE BREATHER Remove all mud and dirt from around the breather, then remove the breather and put it into a cleaning fluid to clean. Take care not to let any dust or dirt get into the transmission case through the port while the breather is removed.
Page 202 MAINTENANCE 3. Drive shaft center support (1 place) 4. Center drive shaft (2 places) 5. Rear drive shaft (2 places) 3-59 WA320-3MC...
Page 203 MAINTENANCE 24.8.4 CHECK ENGINE VALVE CLEARANCE, ADJUST 1. Remove the air crossover tube. 2. Disconnect the support clamps, hose clamp and wastegate sensing line. Remove the crankcase vent tube and any other parts that would prevent removal of the valve cover. 3.
Page 204 MAINTENANCE 5. When the engine timing pin engages the hole in the camshaft gear, Cylinder Number 1 is at TDC on the compression stroke. WARNING Be sure to disengage the engine timing pin after locating TDC to prevent damage to the engine timing pin. 6.
Page 205 MAINTENANCE REMARK Be sure that the timing pin is disengaged to prevent damage to the engine timing pin. 7. Mark the vibration damper and rotate the crankshaft 360 (degrees). Step B Check/Adjust the valves ....I = Intake; E = Exhaust Locknut .
Page 206 MAINTENANCE 11. Install the crankcase vent tube and secure with the support clamps and hose clamp. 12. Install the air crossover tube and any other parts previously removed to gain access to the valve cover. 24.8.5 CHECK TENSION OF DRIVE BELT 1.
Page 207 MAINTENANCE 3. Check the tensioner bearing. NOTE: The tensioner pulley should spin freely under hand pressure with no rough spots detected. 4. Check the fan hub bearing. The fan hub should spin freely without excessive end play. 5. Install the drive belt. 3-64 WA320-3MC...
Page 208 MAINTENANCE 24.9 EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time. 24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM WARNING If the engine was just running, then the coolant could be hot and cause personal injury.
Page 209 MAINTENANCE The radiator cap seals the coolant filler opening of the radiator. Positive sealing requires a cap gasket and its contacting surfaces to be in good condition and a properly tightened cap. The radiator cap incorporates a pressure relief valve. The pressure relief valve keeps the pressure of the coolant at approximately 34 to 64 kPa or 0.35 to 0.65 kg/cm²...
Page 210 MAINTENANCE Open the drain valve (located on the left side of the machine, on the inside of the frame, above the fuel tank) on the engine coolant inlet tube coming from the oil cooler off the bottom of the radiator. Allow the system to completely drain into a suitable container.
Page 211 MAINTENANCE coolant until the radiator is full. 17. Drain and clean the inside of the radiator overflow tank (1). Then add coolant up to the FULL mark. 18. Install the radiator cap as outlined in this section. REMARKS: Always replace the coolant corrosion resistor filter after cleaning and flushing the cooling system and installing new coolant.
Page 212 MAINTENANCE 24.9.2 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT WARNING The oil is hot if the machine has just been operated. Wait for the oil to cool down before changing it. When removing the oil filler cap turn it slowly to release the internal pressure, then remove it carefully.
Page 213 MAINTENANCE Remove mounting bolts (6) of the cover (5) at the top of the tank, then remove the covers. REMARKS: The cover is spring-loaded and could pop off from the force of spring (7), so keep the cover pushed down while removing the bolts.
Page 214 MAINTENANCE Check the hydraulic oil level and add oil to the specified level. For details, see “24.5 EVERY 100 HOURS SERVICE” on page 3-46. Next, increase the engine speed and repeat the procedure in Step 17 to bleed air. Continue this procedure until no more air comes out from plug (10).
Page 215 MAINTENANCE 24.9.4 CHANGE AXLE OIL WARNING The oil is hot if the machine has just been operated. Wait for the oil to cool down before changing it. Set a container to catch the oil under drain plug (P). Remove front and rear oil filler plugs (1), then remove drain plug (P) to drain the oil.
Page 216 MAINTENANCE 24.9.7 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER AND FRESH FILTER Remove both the recirculation filter and the fresh air filter in the same way as when cleaning, and replace them with new parts. For details of cleaning the recirculation air filter, see “24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER”...
Page 217 SPECIFICATIONS WA320-3MC...
Page 218 5160 mm (16 ft 11 in) WEIGHT Operating weight (including 1 operator: 80 kg (176 lb).) (with 14150 kg (31200 lb) bolt on cutting edge) ENGINE Model Komatsu S6D114E-1 Flywheel horsepower 122 kW (166 HP)/2380 Max. torque (gross) 671 N Starting motor 24V 7.5 kW...
Page 219 SPECIFICATIONS WA320-3MC...
Page 220 OPTIONS, ATTACHMENTS WA320-3MC...
Page 221 OPTIONS, ATTACHMENTS OPTIONAL PARTS AND ATTACHMENTS NAME SPECIFICATION, USE Capacity 2.0 m³ (2.6 yd³) Excavating bucket Capacity (with BOC) 2.2 m³ (2.8 yd³) Capacity (for light duty work) 3.0 m³ (3.9 yd³) Light material bucket Capacity (for light duty work, with BOC) 3.2 m³ (4.1 yd³) Bucket tooth Bolt-on tooth - Tip tooth Log lumber grapple...
Page 222 OPTIONS, ATTACHMENTS SELECTING BUCKETS AND TIRES Select the most suitable bucket and tires for the type of work and job site conditions. TYPE OF WORK BUCKET GROUND CONDITIONS TIRE General ground condition 20.5-25-12PR (Rock Loading products Stockpile bucket 20.5-25-12PR Loading and carrying with bolt on edge Leveled ground condition (Traction)
Page 223 OPTIONS, ATTACHMENTS AIR CONDITIONING 28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 28.1.1 FAN SWITCH This can be used to adjust the air flow to four stages. This switc h also acts as the main swi t ch for the air conditioner. When the switch is pressed, the indicator lamp above the switch lights up to indicate the air flow.
Page 224 OPTIONS, ATTACHMENTS 28.1.3 MODE SELECTOR SWITCH This is used to select the vents. The following five vent modes ar e available (left to right in the illustration): FACE FACE/FOOT FOOT FOOT/DEF When the switch is pressed, the indicator lamp above the switc h lights up to display the vent mode.
Page 225 OPTIONS, ATTACHMENTS 28.2 METHOD OF OPERATION Vent Switch Air conditioner Temperature control mode FRESH/RECIRC switch switch switch switch selector switch Condition of use Rapid All blue RECIRC FACE Cooling Normal HI-LO More than half are blue FRESH FACE Dehumidifying, heating HI-LO More than half are red FRESH...
Page 226 OPTIONS, ATTACHMENTS HANDLING ECSS (Electronic Controlled Suspension System) Read this section before using the ECSS in order to use it safely and effectively. 29.1 STRUCTURE AND FUNCTION OF ECSS The ECSS uses the hydraulic spring effect of the hydraulic accumu- lator installed in the circuit at the lift cylinder (1) bottom to absorb the chassis vibration when the machine is traveling.
Page 227 OPTIONS, ATTACHMENTS 29.2 METHOD OF OPERATING ECSS The ECSS switch (1) is on the left side of the panel. When the ECSS switch is pressed, it is turned ON, the pilot lamp (2) (orange) lights up, and the ECSS is actuated. If the sw itch is press again, it is turned off, the pilot lamp goes out, and the ECSS is canceled.
Page 228 OPTIONS, ATTACHMENTS 29.4 ACCUMULATOR PRECAUTIONS WARNING The accumulator is charged with high pressure nitrogen gas, which is extremely dangerous, so read the following items and be careful to handle the accumulator properly. If any problem or failure occurs with the accumulator, contact your distributor immediately.
Page 229 OPTIONS, ATTACHMENTS OPTION DISPLAY The options display is on the left side of the main panel and indicates the condition of actuation of the options. 30.1 EMERGENCY STEERING PILOT LAMP This indicates that the main pump is operating normally when the machine is traveling.
Page 230 OPTIONS, ATTACHMENTS 30.2 RADIO 30.2.1 OPERATING CONTROLS 1. LIQUID CRYSTAL DISPLAY (LCD) PANEL This panel graphically represents all functions selected: radi o frequencies, time and cassette functions. 2. ON-OFF POWER BUTTON This is the primary control for turning the system on and off. 3.
Page 231 OPTIONS, ATTACHMENTS 30.2.2 OPERATION 1. LIQUID CRYSTAL DISPLAY (LCD) PANEL The Liquid Crystal Display Panel is the primary informatio n display: radio frequency being rec eived, time, audio settings and cassette operation (if used). NOTE: Like most LCD equipment, the radio’ s display panel may be affected by extreme cold or exposure to very bright sun- light;...
Page 232 OPTIONS, ATTACHMENTS 6. RADIO BAND SELECTOR (BAND) Radio operation: Press this button to change the radio ban d (FM1, FM2, AM, Weather Band). Cassette operation: Press this button to change manually from side one to side two of a cassette being played. 7 and 8.
Page 233 OPTIONS, ATTACHMENTS E. Repeat the procedure for each button and four bands. You can change any pre-set without affecting the others. It’ s unlikely that more than one We ather Band station will be available in a given area, so most of the Weather Band pre- sets will go unused.
Page 234 OPTIONS, ATTACHMENTS 30.2.5 BATTERY REPLACEMENT Two AA size alkaline batteries in the electro nics module are required to maintain the unit’ s memory when its main power is turned off. Replacement is required when the clock or memory pre-sets fail to keep time or memory.

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