CEBM003602
WA450-3 WHEEL LOADER SERIAL NUMBERS
WA450-3MC - A31001
and up
SERIAL NUMBERS
WA450-3MC - A35001
and up
MATERIAL HANDLER
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.
JULY 1999
Copyright 1999 Komatsu America International Company
FOREWORD
CONTENTS 01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 30-1
40
MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
00-2
WA450-3MC
PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals. Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB005700 PARTS BOOK - MICROFICHE: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BEPM005700 OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM003800 SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM003602 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM006403 SAFETY MANUAL Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 KDC91E is shown on the reverse side of this page.
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO
•
SHIP TO
•
DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
ATTN. STREET ADDRESS
TYPE or PRINT ONLY
•
ORDER DATE
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
IMPORTANT -
SHIPPING METHOD
TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. PARTS BOOK
QTY.
PUBLICATION FORM NO.
P-Paper M-Microfiche
KDC91E 072199
DISTR/BRANCH CODE
PUBLICATION DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
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WA450-3MC
This is the sample of the manual Click on the download link for complete manual
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WA450-3MC
00 FOREWORD SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 HOW TO READ THE SHOP MANUAL . . . . . . . . . . . . . . . . . . . . . 00-5 HOISTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6 COATING MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7 STANDARD TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . 00-9 ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12 CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13
WA450-3MC
00-1
FOREWORD
SAFETY
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
PREPARATIONS FOR WORK
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully before operating the machine.
7. Before adding oil or making repairs, park the machine onhard, level ground, and block the wheels or tracks to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
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, besure to lock all the control levers and hang warning signs on them.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. •
Always 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, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
9. When disassembling or assembling, support the machine 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 oroff the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING 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 starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.
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.
5. Keep all tools in good condition and learn the correct way to use them.
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.
6. 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.
00-2
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative ( ) terminal first. NE G
WA450-3MC
FOREWORD 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 pressure 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. 18. As 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.
WA450-3MC
SAFETY •
When installing hoses and wires, be sure that they willnot be damaged by contact with other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, sobe extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be 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 track separates suddenly, so never let anyone stand at either end of the track.
00-3
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