Shop Manual
WHEELLOADER
SERIALNUMBERSWA320-5LA32001andup
ThismaterialisproprietarytoKomatsuAmericaCorp.andisnottobereproduced,used,ordisclosedexceptin accordancewithwrittenauthorizationfromKomatsuAmericaCorp.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherightto makechangesorimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproducts soldpreviously.
Duetothiscontinuousprogramofresearchanddevelopment,revisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
Copyright2007Komatsu PrintedinU.S.A. KomatsuAmericaCorp. November2007
10STRUCTUREANDFUNCTION.
20TESTING,ADJUSTINGANDTROUBLESHOOTING.
30DISASSEMBLYANDASSEMBLY.
FOREWORD
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SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.Readthe OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readallthe precautionsgivenonthedecalswhicharefixedtothe machine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing. Alwayswearsafetyglasseswhenhittingpartswitha hammer.
Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Beforestarting work,hangUNDERREPAIRsignsonthecontrolsin theoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsand removedparts.Alwayskeepthetoolsandpartsintheir correctplaces.Alwayskeeptheworkareacleanand makesurethatthereisnodirtoroilonthefloor.Smoke onlyintheareasprovidedforsmoking.Neversmoke whileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthemachine onhard,levelground,andblockthewheelsortracksto preventthemachinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketorany otherworkequipmenttotheground.Ifthisisnot possible,insertthesafetypinoruseblockstoprevent theworkequipmentfromfalling.Inaddition,besureto lockallthecontrolleversandhangwarningsignson them.
3.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.
4.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersorsteps,usea standtoprovidesafefooting.
PRECAUTIONSDURINGWORK
1.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthemslowly topreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil,water oraircircuits,firstremovethepressurecompletelyfrom thecircuit.
2.Thewaterandoilinthecircuitsarehotwhentheengine isstopped,sobecarefulnottogetburned.Waitforthe oilandwatertocoolbeforecarryingoutanyworkon theoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthebattery. ALWAYSremovetheleadfromthenegative(-) terminalfirst.
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12 4.Whenraisingheavycomponents,useahoistorcrane.Checkthatthewirerope,chainsandhooksarefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrectplaces.Useahoistor craneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donotworkwithanypartstillraisedby thehoistorcrane.
5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwoboltsin positiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitup immediately.Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.
8.Neveruseflammableliquidstocleanparts,alwaysuseapprovednon-flammablesolventstocleanparts.
9.Besuretoassembleallpartsintheiroriginallocations.Replaceanydamagedpartwithnewparts. Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachineis beingoperated.
10.Wheninstallinghighpressurehoses,besurethattheyarenottwisted.Damagedtubbingdangerous,beextremelycareful wheninstallingtubesforhighpressurecircuits.Alsomakesurepartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorquesandsequences.Wheninstalling protectivepartssuchasguards,orpartsthatmayvibrateorrotateathighspeeds,beparticularlycarefultochecktheir installationcarefully.
12.Whenaligningtwoholes,neverinsertyourfingersorhand.Useappropriatetoolstoalignparts.
13.Whenmeasuringhydraulicpressure,besurethemeasuringtooliscorrectlyassembledbeforetakinganymeasurements.
14.Takecarewhenremovingorinstallingthetracksontrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,neverletanyonestandateitherendofthetrack.
15.Whenmakingrepairsoradjustmentsonelectronicallycontrolledengines,avoidanyphysicalcontactwiththeinjection systemswiringharnesswhiletheengineisrunning.Duetothehighvoltageandamperageinthissystem,seriousinjury mayoccur.
16.Whenremovingthetrack,thetrackseparatessuddenly,soneverletanyonestandateitherendofthetrack.
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.TroubleshootingchartscorrelatingProblemstoCausesarealsoincludedinthis section.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.