Komatsu WA420-3 Wheel Loader Shop Manual VEBM470104

Description

• Model List:
  • WA420-3 Wheel Loader

• 1. COVER
• 2. Contents
• 3. General
• 3.1. Up to SN WA420H30296
• 3.2. Dimensions and weights
• 3.3. Specifications
• 3.4. Weight table
• 3.5. SN WA420H30297 and up
• 3.6. Dimensions and weights
• 3.7. Specifications
• 3.8. Weight table
• 3.9. List of lubricant and water
• 3.10. Outlines of service
• 3.11. General view of controls and gauges
• 3.12. Torque list
• 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. Transmission
• 4.8. Clutch
• 4.9. Transmission control valve
• 4.10. Transmission solenoid valve
• 4.11. Pilot reducing valve
• 4.12. Main relief valve
• 4.13. Torque converter outlet port valve
• 4.14. Priority valve
• 4.15. Transmission oil pressure system diagram
• 4.16. HL selector valve and range selector valve
• 4.17. Emergency manual spool
• 4.18. Electronic control modulation valve
• 4.19. Pilot oil filter
• 4.20. Accumulator valve
• 4.21. Axle mount, center hinge pin
• 4.22. Steering piping
• 4.23. Steering column, orbit roll
• 4.24. Hydraulic circuit diagram for steering
• 4.25. Orbitroll valve
• 4.26. Steering demand valve
• 4.27. Overload relief valve
• 4.28. Steering relief valve
• 4.29. Operation of demand valve
• 4.30. Emergency steering
• 4.31. Brake piping
• 4.32. Brake circuit diagram
• 4.33. Brake valve
• 4.34. Charge valve
• 4.35. Accumulator for system brake
• 4.36. Slack adjuster
• 4.37. Brake circuit diagram
• 4.38. Brake valve (dual circuit)
• 4.39. Brake valve (single circuit)
• 4.40. Brake pressure regulating valve
• 4.41. Accumulator (for brake)
• 4.42. Accumulator for PPC valve
• 4.43. Brake accumulator unit
• 4.44. Brake
• 4.45. Parking brake control
• 4.46. Parking brake
• 4.47. Parking brake valve
• 4.48. Hydraulic piping
• 4.49. Work equipment hydraulic circuit diagram
• 4.50. Work equipment lever linkage
• 4.51. Hydraulic tank
• 4.52. PPC valve
• 4.53. PPC relief valve
• 4.54. Accumulator for PPC valve
• 4.55. Main control valve (up to H30296)
• 4.56. Relief valve (up to H30296
• 4.57. Safety valve (with suction)
• 4.58. Suction valve
• 4.59. Main control valve (H30297 and up)
• 4.60. Safety valve with suction (H30297 and up)
• 4.61. Anticavitation valve (H30297 and up)
• 4.62. Safety valve (H30297 and up)
• 4.63. Hydraulic safety system
• 4.64. Hydraulic safety system location (up to H30431)
• 4.65. Hydraulic safety valve (up to H30431)
• 4.66. Work equipment linkage
• 4.67. Bucket
• 4.68. Bucket positioner and boom kickout
• 4.69. Machine monitor system
• 4.70. Main monitor
• 4.71. Maintenance monitor
• 4.72. Transmission autoshift control system
• 4.73. Transmission controller
• 4.75. Sensors
• 4.76. Engine start circuit
• 4.77. Ether start
• 4.78. Electric transmission control
• 4.79. Combination switch
• 4.80. Kickdown, hold switch
• 4.81. Transmission electric circuit diagram
• 4.82. Transmission cutoff switch
• 4.83. Transmission cutoff function
• 4.84. Electric parking brake control
• 4.85. Airconditioner
• 4.86. Wiring diagrams
• 5. Testing and adjusting
• 5.1. Standard value table for engine
• 5.2. Standard value table for chassis
• 5.3. Test certificate
• 5.4. Standard value table for electrical parts
• 5.5. Tools for testing, adjusting and troubleshooting
• 5.6. Adjusting valve clearance
• 5.7. Measuring compression pressure
• 5.8. Measuring blowby pressure
• 5.9. Testing and adjusting fuel injection timing
• 5.10. Mesuring exhaust color
• 5.11. Measuring intake air pressure (boost pressure)
• 5.12. Measuring engine oil pressure
• 5.13. Testing the fan belt tension
• 5.14. Measuring accelerator pedal
• 5.15. Basic adjustment of accelerator pedal
• 5.16. Measuring operating force, travel of speed lever
• 5.17. Measuring stall speed
• 5.18. Measuring torque converter, transmission, parking brake oil pressure
• 5.19. Method of operating emergency manual spool
• 5.20. Measuring clearance between tyre and wheel
• 5.21. Measuring operating force of steering wheel
• 5.22. Measuring steering oil pressure
• 5.23. Measuring operating force, travel of brake pedal
• 5.24. Measuring brake performance
• 5.25. Testing brake oil pressure
• 5.26. Measuring brake disc wear
• 5.27. Bleeding air from brake system
• 5.28. Measuring parking brake performance
• 5.29. Method of manual release of parking brake
• 5.30. Testing wear of parking brake disc
• 5.31. Measuring work equipment control lever
• 5.32. Measuring PPC valve pressure
• 5.33. Measuring work equipment
• 5.34. Testing and adjusting bucket positioner
• 5.35. Testing and adjusting boom kickout
• 5.36. Adjusting main monitor (speedometer modul)
• 5.37. Checking for abnormality in fuel level sensor
• 5.38. Troubleshooting
• 5.39. Points to remember when troubleshooting
• 5.40. Sequence of events in troubleshooting
• 5.41. Precautions when carrying out maintenance
• 5.42. Handling connectors
• 5.43. Checks before troubleshooting
• 5.44. Method of using troubleshooting charts
• 5.45. Connector types and mounting locations, connector pin arrangement diagram
• 5.46. Connection table for connector pin numbers
• 5.47. Troubleshooting of engine system (S mode)
• 5.48. Troubleshooting of main monitor system (M mode)
• 5.49. Troubleshooting of maintenance monitor system (K mode)
• 5.50. Troubleshooting of electrical system (E mode)
• 5.51. Troubleshooting of transmission controller system (A mode)
• 5.52. Troubleshooting of hydraulic and mechanical system (Chassis related) (T mode)
• 5.53. Troubleshooting of ECSS (Electronically Controlled Suspension System) (D 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
• 6.5. Alternator
• 6.6. Engine oil cooler
• 6.7. Fuel injection pump
• 6.8. Water pump
• 6.9. Turbocharger
• 6.10. Thermostat
• 6.11. Cylinder head
• 6.12. Torque converter charging pump
• 6.13. Torque converter, transmission
• 6.14. Torque converter
• 6.15. Tranmission
• 6.16. Transmission clutch pack
• 6.17. Parking brake
• 6.18. Transmission control valve
• 6.19. Transmission accumulator valve
• 6.20. Drive shaft
• 6.21. Front axle
• 6.22. Rear axle
• 6.23. Front differential
• 6.24. Rear differential
• 6.25. Differential
• 6.26. Final drive
• 6.27. Center hinge pin
• 6.28. Steering, orbit roll
• 6.29. Steering valve
• 6.30. Steering, switch pump
• 6.31. Steering cylinder
• 6.32. Brake valve
• 6.33. Right brake valve (tandem)
• 6.34. Left brake valve (single)
• 6.35. Slack adjuster
• 6.36. Brake
• 6.37. Parking brake disc
• 6.38. Hydraulic tank
• 6.39. Work equipment, PPC pump
• 6.40. PPC valve
• 6.41. Main control valve
• 6.42. Bucket cylinder
• 6.43. Boom cylinder
• 6.44. Hydraulic cylinder
• 6.45. Maintenance monitor
• 6.46. Air conditioner unit
• 6.47. Air conditioner condenser
• 6.48. Dry receiver
• 6.49. Air conditioner compressor
• 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. Diffential
• 7.7. Final drive
• 7.8. Axle mount
• 7.9. Steerig column, orbit roll
• 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. Boom cylinder
• 7.23. Bucket cylinder
• 7.24. Center hinge pin
• 7.25. Work equipment linkage
• 7.26. Bucket
• 7.27. Bucket positioner and boom kickout