Komatsu WA420-3 Wheel Loader Shop Manual CEBM000200

Description

• Model List:
  • WA420-3 Wheel Loader

• 1. MAIN MENU
• 2. CONTENTS
• 3. GENERAL
• 3.1. SPECIFICATION DRAWINGS
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. FUEL, COOLANT AND LUBRICANTS
• 3.5. ENGINE OIL SPECIFICATIONS
• 3.6. DIESEL FUEL SPECIFICATIONS
• 3.7. COOLANT SPECIFICATIONS
• 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. MODULATION VALVE
• 4.11. TRANSMISSION SOLENOID VALVE
• 4.12. ELECTRONIC CONTROL MODULATION VALVE (ECMV)
• 4.13. PILOT OIL FILTER
• 4.14. DRIVE SHAFT
• 4.15. AXLE
• 4.16. DIFFERENTIAL
• 4.17. FINAL DRIVE
• 4.18. AXLE MOUNT, CENTER HINGE PIN
• 4.19. STEERING PIPING
• 4.20. STEERING COLUMN
• 4.21. STEERING VALVE
• 4.22. STEERING VALVE (ORBITROLL)
• 4.23. STOP VALVE
• 4.24. EMERGENCY STEERING PUMP
• 4.25. DIVERTER VALVE
• 4.26. BRAKE PIPING
• 4.27. BRAKE CIRCUIT DIAGRAM
• 4.28. BRAKE VALVE
• 4.29. ACCUMLATOR CHARGE VALVE
• 4.30. ACCUMULATOR (FOR BRAKE)
• 4.31. SLACK ADJUSTER
• 4.32. BRAKE
• 4.33. PARKING BRAKE CONTROL
• 4.34. PARKING BRAKE
• 4.35. PARKING BRAKE SOLENOID VALVE
• 4.36. PARKING BRAKE VALVE
• 4.37. PARKING EMERGENCY RELEASE SOLENOID VALVE
• 4.38. HYDRAULIC PIPING
• 4.39. WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
• 4.40. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 4.41. WORK EQUIPMENT LEVER LINKAGE
• 4.42. HYDRAULIC TANK
• 4.43. PPC VALVE
• 4.44. PPC RELIEF VALVE
• 4.45. ACCUMULATOR (FOR PPC VALVE)
• 4.46. MAIN CONTROL VALVE
• 4.47. WORK EQUIPMENT LINKAGE
• 4.48. BUCKET
• 4.49. BUCKET POSITIONER AND BOOM KICKOUT
• 4.51. AIR CONDITIONER
• 4.52. ELECTRIC CIRCUIT DIAGRAM
• 4.53. WIRING DIAGRAM (EAGLE AIR CONDITIONER/HEATER)
• 4.54. ELECTRIC CIRCUIT DIAGRAM (E.C.S.S.)
• 4.55. ELECTRIC CIRCUIT DIAGRAM (AUTOGREASING)
• 4.56. MACHINE MONITOR SYSTEM
• 4.57. MAIN MONITOR
• 4.58. MAINTENANCE MONITOR
• 4.59. TRANSMISSION AUTOSHIFT CONTROL SYSTEM
• 4.60. TRANSMISSION CONTROLLER
• 4.61. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
• 4.62. SENSORS
• 4.63. ENGINE STARTING CIRCUIT
• 4.64. ENGINE STARTING CIRCUIT (ETHER START)
• 4.65. ELECTRIC TRANSMISSION CONTROL
• 4.66. KICKDOWN, HOLD SWITCH
• 4.67. KICKDOWN ELECTRIC CIRCUIT DIAGRAM
• 4.68. TRANSMISSION CUTOFF SWITCH
• 4.69. TRANSMISSION CUTOFF FUNCTION
• 4.70. 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 TROUBLESHOOTING
• 5.5. MEASURING ENGINE SPEED
• 5.6. MEASURING INTAKE MANIFOLD PRESSURE
• 5.7. MEASURING INTAKE AIR RESTRICTION
• 5.8. MEASURING ENGINE LUBRICATING OIL PRESSURE
• 5.9. MEASURING FUEL FILTER INLET RESTRICTION
• 5.10. MEASURING BLOWBY PRESSURE
• 5.11. MEASURING EXHAUST BACK PRESSURE
• 5.12. MEASURING COOLANT TEMPERATURE
• 5.13. MEASURING AND ADJUSTING VALVE CLEARANCE
• 5.14. MEASURING WASTEGATE ACTUATOR CALIBRATION
• 5.15. MEASURING EXAUST COLOR
• 5.16. MEASURING ACCELERATOR PEDAL
• 5.17. MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
• 5.18. MEASURING STALL SPEEDS
• 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. MEASURING BRAKE DISC WEAR
• 5.29. BLEEDING AIR FROM BRAKE SYSTEM
• 5.30. MEASURING PARKING BRAKE PERFORMANCE
• 5.31. MANUAL RELEASE METHOD FOR PARKING BRAKE
• 5.32. TESTING WEAR OF PARKING BRAKE DISC
• 5.33. MEASURING WORK EQUIPMENT CONTROL LEVER
• 5.34. MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
• 5.35. MEASURING WORK EQUIPMENT
• 5.36. TESTING AND ADJUSTING BUCKET POSITIONER
• 5.37. TESTING AND ADJUSTING BOOM KICKOUT
• 5.38. ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
• 5.39. CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
• 5.40. TROUBLESHOOTING
• 5.40.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.40.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.40.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 5.40.4. HANDLING CONNECTORS
• 5.40.5. CHECKS BEFORE TROUBLESHOOTING
• 5.40.6. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.40.7. CONNECTOR TYPES AND MOUNTING LOCATIONS, CONNECTOR PIN ARRANGEMENT DIAGRAM
• 5.40.8. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.40.9. TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
• 5.40.10. TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
• 5.40.11. TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
• 5.40.12. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.40.13. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)
• 5.40.14. TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)
• 5.40.15. TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)
• 5.40.16. TROUBLESHOOTING EAGLE AIR CONDITIONER
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. TORQUE CONVERTER CHARGING PUMP
• 6.4.1. REMOVAL
• 6.4.2. INSTALLATION
• 6.5. TORQUE CONVERTER, TRANSMISSION
• 6.5.1. REMOVAL
• 6.5.2. INSTALLATION
• 6.6. TORQUE CONVERTER
• 6.7. TRANSMISSION CLUTCH PACK
• 6.8. TRANSMISSION CONTROL VALVE
• 6.8.1. REMOVAL
• 6.8.2. INSTALLATION
• 6.8.3. DISASSEMBLY
• 6.8.4. ASSEMBLY
• 6.9. TRANSMISSION ACCUMULATOR VALVE
• 6.10. FRONT DIFFERENTIAL
• 6.10.1. REMOVAL
• 6.10.2. INSTALLATION
• 6.11. REAR DIFFERENTIAL
• 6.12. CENTER HINGE PIN
• 6.12.1. REMOVAL
• 6.12.2. INSTALLATION
• 6.13. STEERING VALVE (ORBITROLL)
• 6.14. STEERING DEMAND VALVE
• 6.14.1. DISASSEMBLY
• 6.14.2. ASSEMBLY
• 6.15. STEERING SWITCH PUMP
• 6.15.1. REMOVAL
• 6.15.2. INSTALLATION
• 6.16. STEERING CYLINDER
• 6.17. RIGHT BRAKE VALVE (TANDEM)
• 6.17.1. DISASSEMBLY
• 6.17.2. ASSEMBLY
• 6.18. LEFT BRAKE VALVE (SINGLE)
• 6.19. PARKING BRAKE DISC
• 6.20. WORK EQUIPMENT, PPC PUMP
• 6.21. MAIN CONTROL VALVE
• 6.21.1. REMOVAL
• 6.21.2. INSTALLATION
• 6.21.3. DISASSEMBLY
• 6.21.4. ASSEMBLY
• 6.22. BUCKET CYLINDER
• 6.23. HYDRAULIC CYLINDER
• 6.24. MAINTENANCE MONITOR
• 6.24.1. REMOVAL
• 6.24.2. INSTALLATION
• 6.25. AIR CONDITIONER UNIT
• 6.25.1. REMOVAL
• 6.25.2. INSTALLATION
• 6.26. AIR CONDITIONER CONDENSER
• 6.27. AIR CONDITIONER COMPRESSOR
• 6.27.1. REMOVAL
• 6.27.2. 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
• 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