CEBM003502
WA420-3MC WHEEL LOADER MACHINE MODEL
WA420-3MC
SERIAL NUMBERS
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. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
OCTOBER 1999
Copyright 1999 Komatsu America International Company
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WA420-MC
CONTENTS
00
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
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STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
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TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . 20-1
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DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40
MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
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WA420-MC
This is the sample of the manual Click on the download link for complete manual
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WA420-MC
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. THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S). DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPB005600
PARTS BOOK - MICROFICHE: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPB005600
OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEAM003800
SHOP MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEBM003502 CEBM000601
STANDARD MAN-HOUR GUIDE: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WLT70-1
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESSING SYSTEM (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
PUBINFOK.WPT
WA420-3MC
092899
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM AND RETURN TO
•
DataKom Publishing Corporation 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
SHIP TO
PURCHASE ORDER NO.
• ATTN.
TYPE or PRINT ONLY
ORDER DATE
STREET ADDRESS
•
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. PARTS BOOK QTY.
KDC91E 072199
PUBLICATION FORM NO.
P-Paper M-Microfiche
PUBLICATION DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE
IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
6.
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
PREPARATIONS FOR WORK 7.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9.
When disassembling or assembling, support the mac hine with blocks, jacks or stands before starting work.
10.
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the mac hine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. •
A lways wear safety glasses when hitting parts with a hammer.
•
Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, ex perienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before start ing work, hang UNDER REPAIR signs on the controls in the operator's compartment.
Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
5. Keep all tools in good condition and learn the correct way to use them.
WA420-3MC
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SAFETY
SAFETY NOTICE
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
18.
A s a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
19.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. •
20.
When installing high pressure hoses, make sure that t hey are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
21.
W hen assembling or installing parts, always use the specified tightening torques. When installing prot ective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
22.
When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
23.
When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
24.
Take care when removing or installing the tracks of track-type machines. When removing the track, the trac k separates suddenly, so never let anyone stand at either end of the track.
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pres sure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
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When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
WA420-3MC
FOREWORD
GENERAL
FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
WA420-3MC
00-7
This is the sample of the manual Click on the download link for complete manual
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