Komatsu WA420-3 WA420-3H Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA420.zip
Full service and repair manual featuring Electrical Wiring Diagrams for the Komatsu WA420-Series Wheel Loaders, packed with every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
Inside the Komatsu WA420-Series Wheel Loaders workshop service repair manual you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,251 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM000600 - Wheel Loader WA420-3 Operation & Maintenance Manual.pdf
CEAM003700 - Wheel Loader WA420-3 avance plus Operation & Maintenance Manual.pdf
CEBM000200 - Wheel Loader WA420-3 Shop Manual.pdf
SEBM006204 - Wheel Loader WA420-3 avance Shop Manual.pdf
VEAM470400 - Wheel Loader WA420-3H Operation & Maintenance Manual.pdf
VEBM470104 - Wheel Loader WA420-3 Shop Manual.pdf
MAIN SECTIONS
CEAM000600 - Wheel Loader WA420-3 Operation & Maintenance Manual.....2
1. FORWARD.....5
2. SAFETY INFORMATION.....6
3. INTRODUCTION.....7
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....8
5. CONTENTS.....9
SAFETY.....13
6. GENERAL PRECAUTIONS.....14
7. PRECAUTIONS DURING OPERATION.....19
7.1 BEFORE STARTING ENGINE.....19
7.2 OPERATING MACHINE.....21
7.3 TRANSPORTATION.....26
7.4 BATTERY.....27
7.5 TOWING.....28
8. PRECAUTIONS FOR MAINTENANCE.....29
8.1 BEFORE CARRYING OUT MAINTENANCE.....29
8.2 DURING MAINTENANCE.....31
8.3 TIRES.....36
9. POSITION FOR ATTACHING SAFETY LABELS.....38
OPERATION.....42
10. GENERAL VIEW.....43
10.1 GENERAL VIEW OF MACHINE.....43
10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....44
11. EXPLANATION OF COMPONENTS.....45
11.1 MACHINE MONITOR.....45
11.2 SWITCHES.....55
11.3 CONTROL LEVERS AND PEDALS.....61
11.4 STEERING COLUMN TILT LEVER.....65
11.5 CAP WITH LOCK.....66
11.6 SAFETY BAR.....67
11.7 TOWING PIN.....67
11.8 GREASE PUMP.....68
11.9 BACK UP ALARM.....68
11.10 FUSE.....69
11.11 SLOW-BLOW FUSE.....70
12. OPERATION.....71
12.1 CHECKS BEFORE STARTING.....71
12.2 STARTING ENGINE.....84
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....85
12.4 MOVING MACHINE OFF.....86
12.5 CHANGING GEAR SPEED.....88
12.6 CHANGING DIRECTION.....88
12.7 TURNING.....89
12.8 STOPPING MACHINE.....90
12.9 OPERATION OF WORK EQUIPMENT.....91
12.10 WORK POSSIBLE USING WHEEL LOADER.....92
12.11 PRECAUTIONS FOR OPERATION.....97
12.12 ADJUSTING WORK EQUIPMENT POSTURE.....99
12.13 PARKING MACHINE.....101
12.14 CHECKS AFTER COMPLETION OF OPERATION.....102
12.15 STOPPING ENGINE.....102
12.16 CHECK AFTER STOPPING ENGINE.....103
12.17 LOCKING.....103
12.18 HANDLING THE TIRES.....104
13. TRANSPORTATION.....106
13.1 LOADING, UNLOADING WORK.....106
13.2 PRECAUTIONS FOR LOADING.....107
13.3 PRECAUTIONS FOR TRANSPORTATION.....107
14. COLD WEATHER OPERATION.....108
14.1 PRECAUTIONS FOR LOW TEMPERATURE.....108
14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....110
14.3 AFTER COLD WEATHER.....110
15. LONG-TERM STORAGE.....111
15.1 BEFORE STORAGE.....111
15.2 DURING STORAGE.....111
15.3 AFTER STORAGE.....111
16. TROUBLESHOOTING.....112
16.1 WHEN MACHINE RUNS OUT OF FUEL.....112
16.2 TOWING THE MACHINE.....113
16.3 IF BATTERY IS DISCHARGED.....118
16.4 OTHER TROUBLE.....122
MAINTENANCE.....128
17. GUIDES TO MAINTENANCE.....129
18. OUTLINES OF SERVICE.....132
18.1 OUTLINE OF OIL, FUEL, COOLANT.....132
18.2 OUTLINE OF ELECTRIC SYSTEM.....135
19. WEAR PARTS LIST.....136
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....137
20.1 ENGINE OIL SPECIFICATIONS.....139
20.2 DIESEL FUEL SPECIFICATIONS.....140
20.3 COOLANT SPECIFICATIONS.....141
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.....147
21.1 INTRODUCTION OF NECESSARY TOOLS.....147
21.2 TORQUE LIST.....148
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....149
23. MAINTENANCE SCHEDULE CHART.....153
23.1 MAINTENANCE SCHEDULE CHART.....153
24. SERVICE PROCEDURE.....157
24.1 INITIAL 250 HOURS SERVICE.....157
24.2 WHEN REQUIRED.....158
24.3 CHECKS BEFORE STARTING.....167
24.4 EVERY 50 HOURS SERVICE.....168
24.5 EVERY 100 HOURS SERVICE.....169
24.6 EVERY 250 HOURS SERVICE.....171
24.7 EVERY 500 HOURS SERVICE.....177
24.8 EVERY 1000 HOURS SERVICE.....181
24.9 EVERY 2000 HOURS SERVICE.....190
SPECIFICATIONS.....199
25. SPECIFICATIONS.....200
OPTIONAL ATTACHMENTS.....202
26. OPTIONAL PARTS AND ATTACHMENTS.....203
27. SELECTING BUCKETS AND TIRES.....204
28. AIR CONDITIONING .....205
28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.....205
28.2 COOL BOX COMPARTMENT.....206
29. HANDLING E.C.S.S. (ELECTRONIC CONTROL SUSPENSION SYSTEM).....207
29.1 STRUCTURE AND FUNCTION OF E.C.S.S.....207
29.2 METHOD OF OPERATING E.C.S.S.....208
29.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH.....208
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR.....209
30. HANDLING AUTO-GREASING SYSTEM.....210
30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM.....210
30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.....218
30.3 TROUBLESHOOTING.....219
30.4 SPECIFICATIONS.....219
31. OPTION DISPLAY.....220
CEAM003700 - Wheel Loader WA420-3 avance plus Operation & Maintenance Manual.....222
COVER.....222
INTRODUCTION.....225
1. FOREWARD.....226
2. SAFETY INFORMATION.....227
3. INTRODUCTION.....228
3.1 INTENDED USE.....228
3.2 FEATURES.....228
BREAKING IN A NEW MACHINE.....228
4. LOCATION OF PLATES, TABLE FOR SERIAL NUMBER AND DISTRIBUTOR.....229
4.1 MACHINE SERIAL NO. PLATE POSITION.....229
4.2 ENGINE SERIAL NO. PLATE POSITION.....229
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....229
5. TABLE OF CONTENTS.....230
SAFETY.....236
6. GENERAL PRECAUTIONS.....237
7. PRECAUTIONS DURING OPERATION.....243
7.1 BEFORE STARTING ENGINE.....243
7.2 OPERATING MACHINE.....244
7.3 TRANSPORTATION.....253
7.4 BATTERY.....254
7.5 TOWING.....256
8. PRECAUTIONS FOR MAINTENANCE.....257
8.1 BEFORE CARRYING OUT MAINTENANCE.....257
8.2 DURING MAINTENACE.....262
8.3 TIRES.....266
9. SAFETY LABELS.....268
OPERATION.....273
10. GENERAL VIEW.....274
10.1 GENERAL VIEW OF MACHINE.....274
10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....275
11. EXPLANATION OF COMPONENTS.....276
11.1 MACHINE MONITORS.....276
11.1.1 WARNING DISPLAYS.....278
11.1.2 METER DISPLAY PORTION.....282
11.2 SWITCHES.....286
11.3 CONTROL LEVERS, PEDALS.....293
11.4 STEERING COLUMN TILT LEVER.....298
11.5 CAP WITH LOCK.....299
11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK.....299
11.6 SAFETY BAR.....301
11.7 TOWING PIN.....301
11.8 GREASE PUMP.....302
11.9 BACK UP ALARM.....302
11.10 FUSE.....303
11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT.....303
11.11 SLOW-BLOW FUSE.....304
11.12 STORAGE FOR THIS MANUAL.....305
11.13 ELECTRIC POWER (with ROPS CAB.....305
12. OPERATION.....306
12.1 CHECKS BEFORE STARTING.....306
12.1.1 WALK AROUND CHECK.....306
12.1.2 CHECK BEFORE STARTING.....309
12.1.3 ADJUSTMENT BEFORE OPERATION.....314
12.1.4 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....317
12.2 STARTING ENGINE.....319
12.2.1 COLD WEATHER STARTING.....320
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....321
12.4 MOVING MACHINE.....322
12.5 CHANGING GEARS.....324
12.6 CHANGING DIRECTION.....324
12.7 TURNING.....325
12.8 STOPPING MACHINE.....326
12.9 OPERATION OF WORK EQUIPMENT.....327
12.9.1 STANDARD WORK EQUIPMENT CONTROLS.....327
12.9.2 MONO-LEVER WORK EQUIPMENT CONTROLS.....329
12.10 WORK POSSIBLE USING WHEEL LOADER.....330
12.10.1 DIGGING OPERATIONS.....330
12.10.2 LEVELING OPERATION.....333
12.10.3 PUSHING OPERATION.....333
12.10.4 LOAD AND CARRY OPERATION.....333
12.10.5 LOADING OPERATIONS.....334
12.11 PRECAUTIONS FOR OPERATION.....335
12.11.1 PERMISSIBLE WATER DEPTH.....335
12.11.2 IF WHEEL BRAKE DOES NOT WORK.....335
12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.....335
12.11.4 PRECAUTIONS WHEN DRIVING MACHINE.....336
12.12 ADJUSTING WORK EQUIPMENT POSTURE.....337
12.12.1 ADJUSTING BOOM KICKOUT.....337
12.12.2 ADJUSTING BUCKET POSITIONER.....338
12.12.3 BUCKET LEVEL INDICATOR.....338
12.13 PARKING MACHINE.....339
12.14 CHECKS AFTER COMPLETION OF OPERATION.....340
12.15 STOPPING ENGINE.....340
12.16 CHECK AFTER STOPPING ENGINE.....341
12.17 LOCKING.....341
12.18 HANDLING THE TIRES.....342
12.18.1 PRECAUTIONS WHEEN HANDLING TIRES.....342
12.18.2 TIRE PRESSURE.....342
13. TRANSPORTATION.....344
13.1 LOADING AND UNLOADING.....344
13.2 PRECAUTIONS FOR LOADING.....345
13.3 PRECAUTIONS FOR TRANSPORTATION.....345
13.4 LIFTING MACHINE.....345
13.4.1 LOCATION FOR LIFTING POSISTION ECALS.....346
13.4.2 WEIGHT TABLE.....346
13.4.3 LIFTING PROCEDURE.....347
14. COLD WEATHER OPERATION.....348
14.1 PRECAUTIONS FOR LOW TEMPERATURE.....348
14.1.1 FUEL AND LUBRICANTS.....348
14.1.2 COOLANT.....348
14.1.3 BATTERY.....348
14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....349
14.3 AFTER COLD WEATHER.....349
15. LONG TERM STORAGE.....350
15.1 BEFORE STORAGE.....350
15.2 DURING STORAGE.....350
15.3 AFTER STORAGE.....350
16. TROUBLESHOOTING.....351
16.1 WHEN MACHINE RUNS OUT OF FUEL.....351
16.2 TOWING THE MACHINE.....352
16.2.1 WITH THE ENGINE RUNING.....353
16.2.2 WITH THE ENGINE STOPPED.....353
16.2.3 RELEASING PARKING BRAKE.....354
16.2.4 EMERGENCY TRAVEL OPERATION.....355
16.3 IF BATTERY IS DISCHARGED.....356
16.3.1 REMOVAL AND INSTALLATION OF BATTERY.....356
16.3.2 PRECAUTION FOR CHARGING BATTERY.....357
16.3.3 STARTING ENGINE WITH BOOSTER CABLE.....358
16.4 OTHER TROUBLE.....360
16.4.1 ELECTICAL SYSTEM.....360
16.4.2 CHASSIS.....361
16.4.3 ENGINE.....364
MAINTENANCE.....367
17. GUIDES TO MAINTENANCE.....368
18. OUTLINES OF SERVICE.....371
18.1 OUTLINE OF OIL, FUEL, COOLANTS.....371
18.1.1 OIL.....371
18.1.2 FUEL.....372
18.1.3 COOLANT.....372
18.1.4 GREASE.....372
18.1.5 STORING OIL AND FUEL.....373
18.1.6 FILTERS.....373
18.1.7 FUEL INJECTION PUMP.....373
18.2 OUTLINE OF ELECTRIC SYSTEM.....374
19. WEAR PARTS LIST.....375
20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....376
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....376
20.2 ENGINE OIL SPECIFICATION.....377
20.2.1 NORMAL OPERATION.....377
20.2.2 ARCTIC OPERATION.....377
20.3 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.....378
20.4 FINAL DRIVE OIL SPECIFICATION.....378
20.5 DRIVE AXLE OIL SPECIFICATIONS.....378
20.6 DIESEL FUEL SPECIFICATIONS.....378
20.7 COOLANT SPECIFICATIONS.....379
20.7.1 GENERAL.....379
20.7.2 WATER.....379
20.7.3 ANTIFREEZE.....379
20.7.4 SUPPLEMENTAL COOLANT ADDITIVES.....380
21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS.....385
21.1 INTRODUCTION OF NECESSARY TOLS.....385
21.2 TORQUE LIST.....386
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....387
23. MAINTENANCE SCHEDULE.....391
23.1 SCHEDULED MAINTENANCE CHART.....391
24.SERVICE PROCEDURE.....395
24.1 INITIAL 250 HOURS SERVICE.....395
24.2 WHEN REQUIRED.....396
24.2.1 CLEAN OR REPLACE AIR CLEANER ELEMENT.....396
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.....398
24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.....399
24.2.4 CLEAN THE AXLE CASE BREATHER.....400