Komatsu wa420 3 wheel loader service repair manual snwa420 h20051 and up
- 1. WA420-3 Wheel Loader SerialNumber WA420H20051 and up Shop Manual VEBM470104 © 2000 All Rights Reserved Printed in Europe 03/2000
- 2. 00-2 CONTENTS 01 GENERAL......................................................................... 01-1 10 STRUCTURE AND FUNCTION....................................... 10-1 20 TESTING AND ADJUSTING............................................ 20-1 30 DISASSEMBLY AND ASSEMBLY................................... 30-1 40 MAINTENANCE STANDARD........................................... 40-1 No. of page
- 3. 00-3 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. SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE SAFETY SAFETY NOTICE 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, read all the precautions given on the decals which are fixed to the machine. 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. 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. 5. Keep all tools in good condition and learn the correct way to use them. 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. Never smoke while working. Smoke only in the areas provided for smoking. PREPARATIONS FOR WORK 7. Before adding oil or making any 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 and install the safety bar on the frame. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In ad- dition, be sure to lock all the control levers and hang warning signs on them. 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 or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to pro- vide safe footing.
- 4. 00-4 PRECAUTIONS DURING WORK 11. When measuring hydraulic pressure, check that the measuring tool is correctly assembled be- fore taking any measurements. 12. 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. 13. 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 carry- ing out any work on the oil or water circuits. 14. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 15. 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. 16. When removing covers which are under internal pressure or under pressure from a spring, al- ways leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. SAFETY SAFETY NOTICE 17. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 18. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 19. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. Do not smoke! 20. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being oper- ated. 21. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when in- stalling tubes for high pressure circuits. Also, check that connecting parts are correctly in- stalled. 22. When aligning two holes, never insert your fin- gers or hand. Be careful not to get your fingers caught in a hole. 23. 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 particularly careful to check that they are in- stalled correctly.
- 5. 00-5 NOTICE 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. 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. FOREWORD 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. FOREWORD GENERAL
- 6. 00-6 Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Attachments volume: These various volumes are designed to avoid dupli- cating the same information. Therefore, to deal with all repairs for any model , it is necessary that chas- sis, engine, electrical and attachment volumes are available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 10-4-1 10-4-2 10-5 VOLUMES Each issued as one volume to cover all models } HOW TO READ THE SHOP MANUAL FOREWORD HOW TO READ THE SHOP MANUAL SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols. Symbol Item Safety Caution Weight Tightening torque Coat Oil, water Drain Remarks Places where oil or water must be drained, and quantity to be drained. Places where oil, water or fuel must be added, and the capac- ity. Places to be coated with adhe- sives and lubricants, etc. Places that require special at- tention for the tightening torque during assembly. Weight of parts of systems. Caution necessary when select- ing hoisting wire, or when work- ing posture is important, etc. Special technical precautions or other precautions for preserv- ing standards are necessary when performing the work. Special safety precautions are necessary when performing the work. « 12-203 12-203-1 12-203-2 12-204 Added pages
- 7. 00-7 • If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: « The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter (mm) 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load (tons) 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0 Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetri- cally wound onto the load. Slinging with one rope may cause turn- ing of the load during hoisting, untwist- ing of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an exces- sive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. 100% 88% 79% 71% 41% SAD00479 HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 300 600 900 1200 1500 1000 2000 2000 1900 1700 1400 1000 500 kg SAD00480 Lifting angle (α) Load capacity (kg) α FOREWORD HOISTING INSTRUCTIONS
- 8. 01-1 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
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- 10. 01-4 SPECIFICATIONS GENERAL SPECIFICATIONS Machine model WA420-3 Serial No. H30001 - H30296 Operating weight (kg) 20.020 (21.350) Distribution (front) (kg) 10.414 (11.192) Distribution (rear) (kg) 9.600 (9.518) Bucket capacity (heaped) (m3 ) 3.6 Rated load (kg) 5.300 (5.200) Travel speed FORWARD 1st (km/h) 6.8 FORWARD 2nd (km/h) 12.4 FORWARD 3rd (km/h) 22.6 FORWARD 4th (km/h) 39.0 REVERSE 1st (km/h) 7.0 REVERSE 2nd (km/h) 13.1 REVERSE 3rd (km/h) 23.5 REVERSE 4th (km/h) 39.0 Max. rimpull (N (kg)) 166.000 Gradeability (deg) 25 Outside wheel (mm) 6.006 Min. turning radius Outside bucket (mm) 6.579 (6.862) Overall length (mm) 7.937 (8.778) Overall width (wheels) (mm) 2.920 (2.890) Bucket width (mm) 3.000 Overall height (top of cab) (mm) 3.425 (3.445) (Bucket raised) (mm) 5.773 (6.367) Wheelbase (mm) 3.300 Tread (mm) 2.200 Min. ground clearance (mm) 465 Height of bucket hinge pin (mm) 4.186 (4.780) Dumping clearance (at 45°) (mm) 3.080 (3.686) Dumping reach (at 45°) (mm) 966 (1.100) Bucket dump angle (deg) 48 (47) Bucket tilt angle (deg) 64 (60) Digging depth (10° dump) (mm) 38 (140) Weight Performance Dimensions Values in brackets are for High-Lift machine Dimensions and weights for machine with 3,6m³ bucket
- 11. 01-5 Machine model WA420-3 Serial No. H30001 - H30296 Model Cummins 6CTA8.3 Type 4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with turbocharger No. of cylinders – bore x stroke (mm) 6 – 114 mm x 135 mm Piston displacement (cc) 8.268 Flywheel horsepower (kW (PS)/rpm) 167 (228) /2.200 Maximum torque (Nm (kgm)/rpm) 925 (89.4) /1.500 High idling speed (rpm) 2.370 - 2.470 Low idling speed (rpm) 775 - 875 Starting motor 24 V 7.5 kW Alternator 24 V 50 A Battery 12 V 143 Ah x 2 Torque converter 3-element, 1-stage, single-phase (Komatsu TCA37-2Z) Transmission Spur gear, constant-mesh multiple-disc, hydraulically actuated, modulation type Reduction gear Spiral bevel gear, splash lubrication Differential Straight bevel gear, torque proportioning Final drive Planetary gear single stage, splash lubrication Drive type Front-, rear-wheel drive Front wheel Fixed frame, full-floating type Rear wheel Center pin support full-floating type Tire 26.5 R 25 Wheel rim 22.00 Front tire (MPa (bar)) 3.0 * Inflation pressure Rear tire (MPa (bar)) 1.5 * Service brake Front-, rear-wheel independent system control, sealed multiple disc brake Parking brake Drive shaft, wet type disc brake Hydraulically released spring type Engine Power train Brakes Axle, wheel GENERAL SPECIFICATIONS *See the operation and maintenance manual for inflation pressure details
- 12. 01-6 Machine model WA420-3 Serial No. H30001 - H30296 Type Articulated steering Structure Recirculating ball type Hydraulically actuated Hydraulic pump type Gear pump Hydraulic pump 217 Switch pump 111 Delivery ( l /min.) Steering pump 137 PPC/brake pump 62 Set pressure for work equipment 2-spool type (MPa (bar)) 20.58 (210) Set pressure for steering Spool type (MPa (bar)) 20.58 (210) Boom cylinder Reciprocating piston No. – bore x stroke (mm) 2 – 160 x 846 Bucket cylinder Reciprocating piston No. – bore x stroke (mm) 1 – 200 x 498 Steering cylinder Reciprocating piston No. – bore x stroke (mm) 2 – 90 x 442 Link type Single link Bucket edge type Flat edge with BOC Control valve Cylinder Work equipment GENERAL SPECIFICATIONS Steering system Hydraulic system
- 13. 01-7 Machine model WA420-3 Serial No. H30001 -H30296 Engine 790 Radiator 169 Transmission (including torque converter) 1.000 Center drive shaft 36 Front drive shaft 31.2 Rear drive shaft 19 Front axle 1.388 Rear axle 1.376 Front differential 214 Rear differential 224 Planetary carrier (each) 506 Axle pivot (rear axle) 120 Wheel (each) 240 Tire (each) 404 Steering valve 23.5 Steering cylinder (each) 27.7 Brake valve (R.H.) 8.5 Hydraulic tank 165 Hydraulic, PPC pump (tandem pump) 20.5 Steering, switch pump (tandem pump) 23.9 PPC valve 3.54 Main control valve 97 Lift cylinder (each) 153 Bucket cylinder 203 Engine hood 169 Front frame 1.580 Rear frame 1.236 Bucket link 56 Bellcrank 327 Lift arm (including bushing) 1.170 Bucket (with BOC) 1.667 WEIGHT TABLE This weight table is a guide for use when transporting or handling components. Unit: kg GENERAL WEIGHT TABLE
- 14. 01-8 Machine model WA420-3 Serial No. H30001 -H30296 Counterweight 650 Fuel tank 233 Battery (each) 45 Cab 300 Air conditioner unit 12.5 Operator’s seat 38 Floor board 145 Unit: kg GENERAL WEIGHT TABLE
- 15. 01-9 Buckets Bucket capacity as per ISO 7546 m3 3,6 4,0 Pract. filling capacity (100-120%) m3 4,2 -4,32 4,0-4,8 Bucket width m 3,0 3,0 Specific density t/m3 1,75 1,6 Bucket weight w/o teeth kg 1.710 1.840 Stat. tipping weights, straight kg 15.594 15.429 Stat. tipping weights, articulated 40° kg 13.663 13.501 Breakout force hydraulic kN 182,7 171,7 Hydraulic lifting capacity, on ground kN 210 207,1 Operating weight kg 20.152* 20.247* a Reach at full lift 45° mm 1.086 1.143 b Dumping height 45° mm 3.072 3.016 c Lift height, hinge pin mm 4.186 4.186 d Bucket to edge height mm 5.729 5.832 e Digging depth mm 38 38 f Carry height, hinge pin mm 425 425 A Overall length mm 8.022 8.102 B Wheelbase mm 3.300 3.300 C Bucket width mm 3.000 3.000 D Width less bucket mm 2.875 2.875 E Track width mm 2.200 2.200 F Ground clearance mm 465 465 H Overall height mm 3.450 3.450 DIMENSIONS, WEIGHTS AND OPERATING DATA * This dimensions refer to machines with 26,5-25 XHA tyres. The standard buckets shown in the table can be supplied with bold on cutting edge. GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA Special bucket sizes: 3,3 m3 - HD bucket 5,5 m3 - light material bucket SN WA420H30297 and up