Komatsu WA420-3 Avance Loader Shop Manual SEBM006204

Description

• Model List:
  • WA420-3 Avance Loader

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. LIST OF LUBRICANT AND WATER
• 4. STRUCTURE AND FUNCTION
• 4.1. POWER TRAIN
• 4.2. POWER TRAIN SYSTEM
• 4.3. TORQUE CONVERTER, TRANSMISSION PIPING
• 4.4. TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
• 4.5. TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
• 4.6. TORQUE CONVERTER
• 4.7. TORQUE CONVERTER OIL FILTER
• 4.8. TRANSMISSION
• 4.9. TRANSMISSION CONTROL VALVE
• 4.10. TRANSMISSION SOLENOID VALVE
• 4.11. PILOT OIL FILTER
• 4.12. DRIVE SHAFT
• 4.13. AXLE
• 4.14. DIFFERENTIAL
• 4.15. FINAL DRIVE
• 4.16. AXLE MOUNT, CENTER HINGE PIN
• 4.17. STEERING PIPING
• 4.18. STEERING COLUMN
• 4.19. STEERING VALVE
• 4.20. ORBITROLL VALVE
• 4.21. STOP VALVE
• 4.22. EMERGENCY STEERING PUMP
• 4.23. DIVERTER VALVE
• 4.24. BRAKE PIPING
• 4.25. BRAKE CIRCUIT DIAGRAM
• 4.26. BRAKE VALVE
• 4.27. CHARGE VALVE
• 4.28. ACCUMULATOR (FOR BRAKE)
• 4.29. SLACK ADJUSTER
• 4.30. BRAKE
• 4.31. PARKING BRAKE CONTROL
• 4.32. PARKING BRAKE
• 4.33. PARKING BRAKE SOLENOID VALVE
• 4.34. PARKING BRAKE VALVE
• 4.35. PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
• 4.36. HYDRAULIC PIPING
• 4.37. WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
• 4.38. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 4.39. WORK EQUIPMENT LEVER LINKAGE
• 4.40. HYDRAULIC TANK
• 4.41. PPC VALVE
• 4.42. PPC RELIEF VALVE
• 4.43. ACCUMULATOR (FOR PPC VALVE)
• 4.44. MAIN CONTROL VALVE
• 4.45. WORK EQUIPMENT LINKAGE
• 4.46. BUCKET
• 4.47. BUCKET POSITIONED AND BOOM KICKOUT
• 4.49. ROPS CAB
• 4.50. AIR CONDITIONER
• 4.51. ELECTRIC CIRCUIT DIAGRAM
• 4.52. MACHINE MONITOR SYSTEM
• 4.53. MAIN MONITOR
• 4.54. MAINTENANCE MONITOR
• 4.55. WORK EQUIPMENT CONTROL SYSTEM
• 4.56. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
• 4.57. SENSORS
• 4.58. ENGINE STARTING CIRCUIT
• 4.59. ENGINE STOP CIRCUIT
• 4.60. PREHEATING CIRCUIT
• 4.61. ELECTRIC TRANSMISSION CONTROL
• 4.62. KICKDOWN SWITCH
• 4.63. KICKDOWN ELECTRIC CIRCUIT DIAGRAM
• 4.64. TRANSMISSION CUTOFF SWITCH
• 4.65. TRANSMISSION CUTOFF FUNCTION
• 4.66. ELECTRIC PARKING BRAKE CONTROL
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. STANDARD VALUE TABLE FOR ELECTRICAL PARTS
• 5.4. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 5.5. ADJUSTING VALVE CLEARANCE
• 5.6. MEASURING COMPRESSION PRESSURE
• 5.7. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.8. MEASURING EXHAUST COLOR
• 5.9. MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
• 5.10. MEASURING BLOWBY PRESSURE
• 5.11. TESTING AND ADJUSTING FAN BELT TENSION
• 5.12. MEASURING ENGINE SPEED
• 5.13. METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
• 5.14. MEASURING ENGINE OIL PRESSURE
• 5.15. MEASURING EXHAUST GAS TEMPERATURE
• 5.16. MEASURING ACCELERATOR PEDAL
• 5.17. MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
• 5.18. MEASURING STALL SPEED
• 5.19. MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE
• 5.20. METHOD OF OPERATING EMERGENCY MANUAL SPOOL
• 5.21. MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
• 5.22. TESTING AND ADJUSTING STEERING WHEEL
• 5.23. TESTING AND ADJUSTING STEERING CONTROL
• 5.24. MEASURING STEERING OIL PRESSURE
• 5.25. MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
• 5.26. MEASURING BRAKE PERFORMANCE
• 5.27. TESTING BRAKE OIL PRESSURE
• 5.28. TESTING FOR BRAKE DISC WEAR
• 5.29. BLEEDING AIR FROM BRAKE SYSTEM
• 5.30. TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
• 5.31. MEASURING PARKING BRAKE PERFORMANCE
• 5.32. METHOD FOR MANUAL RELEASE OF PARKING BRAKE
• 5.33. TESTING WEAR OF PARKING BRAKE DISC
• 5.34. MEASURING WORK EQUIPMENT CONTROL LEVER
• 5.35. MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
• 5.36. MEASURING WORK EQUIPMENT
• 5.37. TESTING AND ADJUSTING BUCKET POSITIONER
• 5.38. TESTING AND ADJUSTING BOOM KICKOUT
• 5.39. ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
• 5.40. CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
• 5.41. ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER
• 5.42. TROUBLESHOOTING
• 5.42.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.42.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.42.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 5.42.4. HANDLING CONNECTORS
• 5.42.5. CHECKS BEFORE TROUBLESHOOTING
• 5.42.6. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.42.7. CONNECTOR TYPES AND MOUNTING LOCATIONS
• 5.42.8. CONNECTOR PIN ARRANGEMENT DIAGRAM
• 5.42.9. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.42.10. TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
• 5.42.11. TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
• 5.42.12. TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
• 5.42.13. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.42.14. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)
• 5.42.15. TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)
• 5.42.16. TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. STARTING MOTOR
• 6.4.1. REMOVAL AND INSTALLATION
• 6.5. ALTERNATOR
• 6.5.1. REMOVAL AND INSTALLATION
• 6.6. ENGINE OIL COOLER
• 6.6.1. REMOVAL AND INSTALLATION
• 6.7. AFTERCOOLER CORE
• 6.7.1. REMOVAL AND INSTALLATION
• 6.8. FUEL INJECTION PUMP
• 6.8.1. REMOVAL
• 6.8.2. INSTALLATION
• 6.9. WATER PUMP
• 6.9.1. REMOVAL AND INSTALLATION
• 6.10. TURBOCHARGER
• 6.10.1. REMOVAL AND INSTALLATION
• 6.11. NOZZLE HOLDER
• 6.11.1. REMOVAL AND INSTALLATION
• 6.12. THERMOSTAT
• 6.12.1. REMOVAL AND INSTALLATION
• 6.13. TORQUE CONVERTER CHARGING PUMP
• 6.13.1. REMOVAL
• 6.13.2. INSTALLATION
• 6.14. TORQUE CONVERTER, TRANSMISSION
• 6.14.1. REMOVAL
• 6.14.2. INSTALLATION
• 6.15. TORQUE CONVERTER
• 6.16. TRANSMISSION CLUTCH PACK
• 6.17. TRANSMISSION CONTROL VALVE
• 6.17.1. REMOVAL
• 6.17.2. INSTALLATION
• 6.17.3. DISASSEMBLY
• 6.17.4. ASSEMBLY
• 6.18. TRANSMISSION ACCUMULATOR VALVE
• 6.19. FRONT DIFFERENTIAL
• 6.19.1. REMOVAL
• 6.19.2. INSTALLATION
• 6.20. REAR DIFFERENTIAL
• 6.21. CENTER HINGE PIN
• 6.22. STEERING DEMAND VALVE
• 6.22.1. DISASSEMBLY
• 6.22.2. ASSEMBLY
• 6.23. STEERING,SWITCH PUMP
• 6.23.1. REMOVAL
• 6.23.2. INSTALLATION
• 6.24. STEERING CYLINDER
• 6.25. RIGHT BRAKE VALVE (TANDEM)
• 6.25.1. DISASSEMBLY
• 6.25.2. ASSEMBLY
• 6.26. LEFT BRAKE VALVE (SINGLE)
• 6.27. PARKING BRAKE DISC
• 6.27.1. REMOVAL
• 6.27.2. INSTALLATION
• 6.28. ACCUMULATOR CHARGE VALVE
• 6.28.1. REMOVAL AND INSTALLATION
• 6.29. WORK EQUIPMENT,PPC PUMP
• 6.30. MAIN CONTROL VALVE
• 6.30.1. REMOVAL
• 6.30.2. INSTALLATION
• 6.30.3. DISASSEMBLY
• 6.30.4. ASSEMBLY
• 6.31. BUCKET CYLINDER
• 6.31.1. REMOVAL AND INSTALLATION
• 6.32. MAINTENANCE MONITOR
• 6.32.1. REMOVAL AND INSTALLATION
• 6.33. AIR CONDITIONER UNIT
• 6.33.1. REMOVAL
• 6.33.2. INSTALLATION
• 6.34. AIR CONDITIONER CONDENSER
• 6.34.1. REMOVAL
• 6.34.2. INSTALLATION
• 6.35. DRY RECEIVER
• 6.35.1. REMOVAL AND INSTALLATION
• 6.36. AIR CONDITIONER CONDENSER COMPRESSOR
• 6.36.1. REMOVAL
• 6.36.2. INSTALLATION
• 7. MAINTENANCE STANDARD
• 7.1. ENGINE MOUNT, TRANSMISSION MOUNT
• 7.2. TORQUE CONVERTER
• 7.3. TRANSMISSION
• 7.4. TRANSMISSION CONTROL VALVE
• 7.5. DRIVE SHAFT
• 7.6. DIFFERENTIAL
• 7.7. FINAL DRIVE
• 7.8. AXLE MOUNT
• 7.9. STEERING COLUMN
• 7.10. STEERING VALVE
• 7.11. STEERING CYLINDER MOUNT
• 7.12. SLACK ADJUSTER
• 7.13. BRAKE VALVE (SINGLE)
• 7.14. BRAKE
• 7.15. PARKING BRAKE
• 7.16. TORQUE CONVERTER,TRANSMISSION PUMP
• 7.17. STEERING,SWITCH PUMP
• 7.18. HYDRAULIC,PPC PUMP
• 7.19. PPC VALVE
• 7.20. CUTOFF VALVE
• 7.21. MAIN CONTROL VALVE
• 7.22. HYDRAULIC CYLINDER
• 7.23. CENTER HINGE PIN
• 7.24. WORK EQUIPMENT LINKAGE
• 7.25. BUCKET
• 7.26. BUCKET POSITIONER AND BOOM KICKOUT