WA420-3MC

WHEELLOADER

MACHINEMODELSERIALNUMBERS WA420-3MCA31001andup

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MARPAGEREVMARPAGEREVMARPAGEREVMARPAGEREV O30-1•O30-50•O30-99•O30-149• O30-2•O30-51•O30-100•O30-150• O30-3•O30-52•O30-101•O30-151• O30-4•O30-53•O30-102•O30-152• O30-5•O30-54•O30-103•O30-153• O30-6•O30-55•O30-104•O30-154• O30-7•O30-56•O30-105•O30-155• O30-8•O30-57•O30-106•O30-156• O30-9•O30-58•O30-107•O30-157• O30-10•O30-59•O30-108•O30-158• O30-11•O30-60•O30-109•O30-159• O30-12•O30-61•O30-110•O30-160• O30-13•O30-62•O30-112•O30-161• O30-14•O30-63•O30-113•O30-162• O30-15•O30-64•O30-114•O30-163• O30-16•O30-65•O30-115•O30-164• O30-17•O30-66•O30-116•O30-165• O30-18•O30-67•O30-117•O30-166• O30-19•O30-68•O30-118•O30-167• O30-20•O30-69•O30-119•O30-168• O30-21•O30-70•O30-120•O30-169• O30-22•O30-71•O30-121•O30-170• O30-23•O30-72•O30-122•O30-171• O30-24•O30-73•O30-123•O30-172• O30-25•O30-74•O30-124•O30-173• O30-26•O30-75•O30-125•O30-174• O30-27•O30-76•O30-126•O30-175• O30-28•O30-77•O30-127•O30-176• O30-29•O30-78•O30-128•O30-177• O30-30•O30-79•O30-129•O30-178• O30-31•O30-80•O30-130•O30-179• O30-32•O30-81•O30-131•O30-180• O30-33•O30-82•O30-132•O30-181• O30-34•O30-83•O30-133•O30-182• O30-35•O30-84•O30-134•O30-183• O30-36•O30-85•O30-135•O30-184• O30-37•O30-86•O30-136•O30-185• O30-38•O30-87•O30-137•O30-186• O30-39•O30-88•O30-138•O30-187• O30-40•O30-89•O30-139•O30-188• O30-41•O30-90•O30-140•O30-189• O30-42•O30-91•O30-141•O30-190• O30-43•O30-92•O30-142•O30-191• O30-44•O30-93•O30-143•O30-192• O30-45•O30-94•O30-144•O30-193• O30-46•O30-95•O30-145•O30-194• O30-47•O30-96•O30-146•O30-195• O30-48•O30-97•O30-147•O30-196• O30-49•O30-98•O30-148•O30-197•

MARPAGEREVMARPAGEREVMARPAGEREVMARPAGEREV O30-198•O30-246•40-140-50 O30-199•O30-247•40-2 O30-200•O30-248•40-3 O30-201•O30-249•40-4 O30-202•O30-250•40-5 O30-203•O30-251•40-6 O30-204•O30-252•40-7 O30-205•O30-253•40-8 O30-206•O30-254•40-9 O30-207•O30-255•40-10 O30-208•O30-256•40-11 O30-209•O30-257•40-12 O30-210•O30-258•40-13 O30-211•O30-259•40-14 O30-212•O30-260•40-15 O30-213•O30-261•40-16 O30-214•O30-262•40-17 O30-215•O30-263•40-18 O30-216•O30-264•40-19 O30-217•40-20 O30-218•40-21 O30-219•40-22 O30-220•40-23 O30-221•40-24 O30-222•40-25 O30-223•40-26 O30-224•40-27 O30-225•40-28 O30-226•40-29 O30-227•40-30 O30-228•40-31 O30-229•40-32

O30-230•40-33 O30-231•40-34 O30-231•40-35 O30-232•40-36 O30-233•40-37 O30-234•40-38 O30-235•40-39

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PRODUCTPUBLICATIONSINFORMATION

VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATIONANDMAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.

SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSERVICE MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&SERVICEMANUALSINFOREIGN LANGUAGES.

THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).

PARTSANDSERVICEPUBLICATIONSCANONLYBEACQUIREDBYAUTHORIZEDKOMATSU DISTRIBUTORS,USINGTHEKOMATSUAMERICAINTERNATIONALCOMPANYPARTSINVENTORY PROCESSINGSYSTEM(PIPS). IFTHEPIPSSYSTEMISNOTAVAILABLEATTHEDISTRIBUTORLOCATION,THENTHEFOLLOWING REQUISITIONFORTECHNICALSERVICEPUBLICATIONSANDSERVICEFORMSCANBEUSED.FORM KDC91DISSHOWNONTHEREVERSESIDEOFTHISPAGE.

COMPLETEFORM ANDRETURNTO

SHIPTO

•DataKomPublishingCorporation

440NorthFairwayDrive

VernonHills,IL60061-8112U.S.A.

Attn:TechnicalPublications

FaxNo.(847)970-4186

TelNo.(847)970-5887

COMPANYNAME ATTN.

IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN.

SAFETY

SAFETYNOTICE

IMPORTANTSAFETYNOTICE

Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Some oftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.

Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.

GENERALPRECAUTIONS

6.Decideaplaceintherepairworkshoptokeeptools

Mistakesinoperationareextremelydangerous.Readthepartsintheircorrectplaces.Alwayskeepthework OPERATION&MAINTENANCEMANUALcarefullyareacleanandmakesurethatthereisnodirtoroil BEFOREoperatingthemachine.onthefloor.Smokeonlyintheareasprovidedfor

1.Beforecarryingoutanygreasingorrepairs,readall theprecautionsgivenonthedecalswhicharefixedto

PREPARATIONSFORWORK themachine.

7.Beforeaddingoilormakingrepairs,parkthe

2.Whencarryingoutanyoperation,alwayswearsafetymachineonhard,levelground,andblockthe shoesandhelmet.Donotwearlooseworkclothes,wheelsortrackstopreventthemachinefrom orclotheswithbuttonsmissing.moving.

•Alwayswearsafetyglasseswhenhittingparts withahammer.

•Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.

3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.When carryingoutweldingwork,alwayswearwelding gloves,apron,glasses,capandotherclothessuited forweldingwork.

4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Before startingwork,hangUNDERREPAIRsignsonthe controlsintheoperator'scompartment.

8.Beforestartingwork,lowerblade,ripper,bucketor anyotherworkequipmenttotheground.Ifthisis notpossible,insertthesafetypinoruseblocksto preventtheworkequipmentfromfalling.Inaddition, besuretolockallthecontrolleversandhang warningsignsonthem.

9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbefore startingwork.

10.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine.Always usethehandrails,laddersorstepswhengettingon oroffthemachine.Neverjumponoroffthe machine.Ifitisimpossibletousethehandrails, laddersorsteps,useastandtoprovidesafe footing.

5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem. andremovedparts.Alwayskeepthetoolsand smoking.Neversmokewhileworking.

PRECAUTIONSDURINGWORK

11.Whenremovingtheoilfillercap,drainplugor18.Asageneralrule,donotusegasolinetowash hydraulicpressuremeasuringplugs,loosenthemparts.Inparticular,useonlytheminimumof slowlytopreventtheoilfromspurtingout.Beforegasolinewhenwashingelectricalparts. disconnectingorremovingcomponentsoftheoil, wateroraircircuits,firstremovethepressure19.Besuretoassembleallpartsagainintheiroriginal completelyfromthecircuit.places.Replaceanydamagedpartwithnewparts.

12.Thewaterandoilinthecircuitsarehotwhenthe engineisstopped,sobecarefulnottogetburned. Waitfortheoilandwatertocoolbeforecarryingout anyworkontheoilorwatercircuits.

13.Beforestartingwork,removetheleadsfromthe battery.ALWAYSremovetheleadfromthenegative (-)terminalfirst.

14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.Alwaysuseliftingequipment whichhasamplecapacity.Installthelifting equipmentatthecorrectplaces.Useahoistorcrane andoperateslowlytopreventthecomponentfrom hittinganyotherpart.Donotworkwithanypartstill raisedbythehoistorcrane.

15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.

16.Whenremovingcomponents,becarefulnottobreak ordamagethewiring,Damagedwiringmaycause electricalfires.

17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause youtoslip,orcanevenstartfires.

•Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.

20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesare dangerous,sobeextremelycarefulwheninstalling tubesforhighpressurecircuits.Alsocheckthat connectingpartsarecorrectlyinstalled.

21.Whenassemblingorinstallingparts,alwaysuse thespecifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,be particularlycarefultocheckthattheyareinstalled correctly.

22.Whenaligningtwoholes,neverinsertyourfingers orhand.Becarefulnottogetyourfingerscaughtin ahole.

23.Whenmeasuringhydraulicpressure,checkthat themeasuringtooliscorrectlyassembledbefore takinganymeasurements.

24.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyone standateitherendofthetrack.

FOREWORD

GENERAL

Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.

Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.

GENERAL

Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.

STRUCTUREANDFUNCTION

Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.

TESTINGANDADJUSTING

Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeatcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"are alsoincludedinthissection.

DISASSEMBLYANDASSEMBLY

Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.

MAINTENANCESTANDARD

Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.

NOTICE

Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.