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Shop Manual
WA420-3
Wheel Loader
Serial Number
WA420H20051 and up
© 2000
All Rights Reserved
Printed in Europe 03/2000
CONTENTS
No. of page
01 GENERAL ......................................................................... 01-1
00-2
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. Some of the
described service and repair techniques require the use of tools specially designed by
Komatsu for the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this
manual. The cautions accompanying these symbols must always be followed carefully. If any
dangerous situation arises or may possibly arise, first consider safety, and take the neces-
sary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION AND MAINTENANCE MANUAL
carefully BEFORE operating the machine!
Always follow the safety rules valid in your country carefully!
1. Before carrying out any greasing or repairs, Always keep the work area clean and make
read all the precautions given on the decals sure that there is no dirt or oil on the floor.
which are fixed to the machine. Never smoke while working.
Smoke only in the areas provided for smoking.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
PREPARATIONS FOR WORK
• Always wear safety glasses when hitting parts
with a hammer.
7. Before adding oil or making any repairs, park
• Always wear safety glasses when grinding
the machine on hard, level ground, and block
parts with a grinder, etc.
the wheels or tracks to prevent the machine
3. If welding repairs are needed, always have a from moving.
trained, experienced welder carry out the work.
8. Before starting work, lower blade, ripper, bucket
When carrying out welding work, always wear
or any other work equipment to the ground and
welding gloves, apron, glasses, cap and other
install the safety bar on the frame. If this is not
clothes suited for welding work.
possible, insert the safety pin or use blocks to
4. When carrying out any operation with two or prevent the work equipment from falling. In ad-
more workers, always agree on the operating dition, be sure to lock all the control levers and
procedure before starting. Always inform your hang warning signs on them.
fellow workers before starting any step of the
9. When disassembling or assembling, support the
operation. Before starting work, hang UNDER
machine with blocks, jacks or stands before
REPAIR signs on the controls in the operator's
starting work.
compartment.
10. Remove all mud and oil from the steps or other
5. Keep all tools in good condition and learn the
places used to get on and off the machine.
correct way to use them.
Always use the handrails, ladders or steps when
6. Decide a place in the repair workshop to keep getting on or off the machine. Never jump on or
tools and removed parts. Always keep the tools off the machine. If it is impossible to use the
and parts in their correct places. handrails, ladders or steps, use a stand to pro-
vide safe footing.
00-3
SAFETY SAFETY NOTICE
11. When measuring hydraulic pressure, check that 17. When removing components, be careful not to
the measuring tool is correctly assembled be- break or damage the wiring. Damaged wiring
fore taking any measurements. may cause electrical fires.
12. When removing the oil filler cap, drain plug or 18. When removing piping, stop the fuel or oil from
hydraulic pressure measuring plugs, loosen them spilling out. If any fuel or oil drips onto the floor,
slowly to prevent the oil from spurting out. wipe it up immediately. Fuel or oil on the floor
Before disconnecting or removing components can cause you to slip, or can even start fires.
of the oil, water or air circuits, first remove the
19. As a general rule, do not use gasoline to wash
pressure completely from the circuit.
parts. In particular, use only the minimum of
13. The water and oil in the circuits are hot when gasoline when washing electrical parts. Do not
the engine is stopped, so be careful not to get smoke!
burned.
20. Be sure to assemble all parts again in their
Wait for the oil and water to cool before carry-
original places.
ing out any work on the oil or water circuits.
Replace any damaged parts with new parts.
14. Before starting work, remove the leads from • When installing hoses and wires, be sure
the battery. Always remove the lead from the that they will not be damaged by contact with
negative (–) terminal first. other parts when the machine is being oper-
15. When raising heavy components, use a hoist or ated.
crane. 21. When installing high pressure hoses, make sure
Check that the wire rope, chains and hooks are that they are not twisted. Damaged tubes are
free from damage. dangerous, so be extremely careful when in-
Always use lifting equipment which has ample stalling tubes for high pressure circuits. Also,
capacity. check that connecting parts are correctly in-
Install the lifting equipment at the correct places. stalled.
Use a hoist or crane and operate slowly to
22. When aligning two holes, never insert your fin-
prevent the component from hitting any other
gers or hand. Be careful not to get your fingers
part. Do not work with any part still raised by
caught in a hole.
the hoist or crane.
16. When removing covers which are under internal 23. When assembling or installing parts, always use
pressure or under pressure from a spring, al- the specified tightening torques. When installing
ways leave two bolts in position on opposite protective parts such as guards, or parts which
sides. Slowly release the pressure, then slowly vibrate violently or rotate at high speed, be
loosen the bolts to remove. particularly careful to check that they are in-
stalled correctly.
00-4
F O R EW OR D GENERAL
F O R EW OR D
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel
an accurate understanding of the product and by showing them 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 chapters; these chapters are
further divided into the each main group of components.
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. Use the specifications given in the book with the latest
date.
00-5
F O R EW OR D HOW TO READ THE SHOP MANUAL
12 - 5
Unit number (1. Engine)
Item number (2. Testing and
Adjusting)
Consecutive page number for
each item.
00-6
F O R EW OR D HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause
Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting,
with a hoist, etc. In the DISASSEMBLY and a serious accident can result. Hooks
AND ASSEMBLY section, every part have maximum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
2000
1900
1700
2000
1400
« The allowable load value is estimated to be
1000
one-sixth or one-seventh of the breaking
1000
strength of the rope used. 500
00-7
01 GENERAL
Up to SN WA420H30296:
Dimensions and weights ................................. 01- 2
Specifications ................................................. 01- 4
Weight table ................................................... 01- 7
SN WA420H30297 and up:
Dimensions and weights ................................. 01- 9
Specifications .................................................01-10
Weight table ................................................... 01-13
List of lubricant and water .............................01-15
Outlines of service .........................................01-17
General view of controls and gauges ...........01-20
Torque list .................................................... 01-22
01-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
Values in brackets are for High-Lift machine
Dimensions and weights for machine with 3,6m³ bucket
Gradeability (deg) 25
01-4
GENERAL SPECIFICATIONS
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Transmission
hydraulically actuated, modulation type
Tire 26.5 R 25
*See the operation and maintenance manual for inflation pressure details
01-5
GENERAL SPECIFICATIONS
PPC/brake pump 62
Control valve
01-6
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine 790
Radiator 169
Bucket link 56
Bellcrank 327
01-7
GENERAL WEIGHT TABLE
Unit: kg
Counterweight 650
Battery (each) 45
Cab 300
Operator’s seat 38
01-8
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
Buckets
01-9
GENERAL SPECIFICATIONS
SPECIFICATIONS
Dimensions and weights for machine with 3,6m³ bucket
Gradeability (deg) 25
01-10
GENERAL SPECIFICATIONS
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Transmission
hydraulically actuated, modulation type
Tire 26.5 R 25
* See the operation and maintenance manual for inflation pressure details
** New values not yet available when printing
01-11
GENERAL SPECIFICATIONS
PPC/brake pump 62
Control valve
01-12
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine 658
Radiator 169
Bucket link 56
Bellcrank 327
01-13
GENERAL WEIGHT TABLE
Unit: kg
Counterweight 650
Battery (each) 45
Cab 670
01-14
GENERAL LUBRICATING AND OPERATING MEANS
CCMC D4
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W 60
API CD
Hydraulic oil HYD HYD 0530 HVLP, HVLP D -35° to 50° C ISO VG 46 *)
CCMC D4
or engine oil EO EO 10 or, if not available, -35° to 40° C SAE 10W
Hydraulic system, 210
API CD
steering, brakes (138**)
HEES
or hydraulic oil ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50° C
BIO-E-HYD
technology)
01-15
GENERAL LUBRICATING AND OPERATING MEANS
Axle oils (AXO) - The selection of the oils depends on the equipment of the axle:
For reasons of harmonization, engine oil in accordance API CD/SAE 30 may be used in the standard axle
instead of axle oil. Any noises from the brakes do not affect the life.
The use of not recommended axle oils may cause unnormal noises from the differential.
01-16
GENERAL OUTLINES OF SERVICE
Oil
• Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high
pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature given in the Operation and Maintenance Manual.
Even if the oil is not dirty, always replace the oil after the specified interval.
• Oil can be compared to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from penetrating.
The majority of problems with machines are caused by the entry of such impurities.
Take particular care not to let any impurities penetrate when storing or adding oil.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such
cases, please contact your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend to have an analysis of the oil made periodically to check the condition of the machine.
Those who wish to use this service, are requested to their Komatsu distributor.
FUEL
• The fuel pump is a precision instrument; if fuel containing water or dirt is used, it cannot work properly.
• Be extremely careful not to let impurities penetrate when storing or adding fuel.
• Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature (particularly at low temperatures below -15 °C), so
change to a fue matching this temperature.
• 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.
• Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and
water from the fuel tank.
• If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the
circuit.
• If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal.
If the fuel sulphur content is more 1.0 %, the oil change interval must be 1/4 normal.
01-17
GENERAL OUTLINES OF SERVICE
COOLANT
• River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the
engine and radiator causing a defective heat exchange and overheating.
• When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.
• Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is
shipped.
This anti-freeze prevents corrosion in the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is
even in hot areas.
• Anti- freeze is flammable, so be extremely careful not to expose it to open flame or fire.
• If the engine overheats, wait for the engine to cool before adding coolant.
• If the coolant level is low, it will cause overheating and corrosion due to the air in the coolant.
GREASE
• Grease is used to prevent twisting and noise at the joints.
• The nipples not included in the maintenance section are nipples for overhaul, so they need not be lubricated.
If any part becomes stiff after being used for a long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off
the old grease in places where sand or dirt in the grease would cause the rotating parts to wear.
• When keeping barrels for a long period, lay down the barrel on its side so that the filler port is at the side
(to prevent moisture from being sucked in).
If barrels have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
• To prevent any change in quality during long term storage, be sure to use in the order of 'first in - first out'
(use the oldest oil or fuel first).
01-18
GENERAL OUTLINES OF SERVICE
• Maintenance work at the electric system includes: (1) check fan belt tension, (2) check damage or wear to
the fan belt and (3) check battery fluid level.
• 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 is raining.
• When working on the seashore, carefully clean the electric system to prevent corrosion.
• The optional power source must never be connected to the fuse, starter switch, or battery relay.
01-19
GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
35
H S Ec
50 Fuel gauge
51 Engine cooling water temperature gauge
52 Torque converter oil temperature gauge
57 Service meter
58 Air cleaner clogging warning pilot lamp
59 Charge monitor
60 Brake oil pressure warning pilot lamp
61 Engine oil pressure warning lamp
62 Engine oil level warning pilot lamp
63 Engine water level warning lamp
MAINTENANCE MONITOR
01-20
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