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KOMATSU AVANCE LOADER WA420-3 SHOP MANUAL SEBM006204 – PDF DOWNLOAD
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Description
KOMATSU AVANCE LOADER WA420-3 SHOP MANUAL SEBM006204 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU AVANCE LOADER WA420-3 SHOP MANUAL SEBM006204 – PDF DOWNLOAD
Language : English
Pages : 828
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA420-3 SHOP MANUAL SEBM006204 – PDF DOWNLOAD
COVER.................................................................................................................................................................. 1 CONTENTS............................................................................................................................................................... 2 01 GENERAL............................................................................................................................................................. 25 GENERAL ASSEMBLY DRAWING........................................................................................................................................... 26 SPECIFICATIONS..................................................................................................................................................... 28 WEIGHT TABLE....................................................................................................................................................... 31 LIST OF LUBRICANT AND WATER........................................................................................................................................ 33 10 STRUCTURE AND FUNCTION.............................................................................................................................................. 35 POWER TRAIN........................................................................................................................................................ 36 POWER TRAIN SYSTEM................................................................................................................................................. 37 TORQUE CONVERTER, TRANSMISSION PIPING.............................................................................................................................. 39 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.............................................................................................................................. 40 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................. 41 TORQUE CONVERTER................................................................................................................................................... 42 TORQUE CONVERTER OIL FILTER........................................................................................................................................ 45 TRANSMISSION....................................................................................................................................................... 46 TRANSMISSION CONTROL VALVE......................................................................................................................................... 56 TRANSMISSION SOLENOID VALVE........................................................................................................................................ 77 PILOT OIL FILTER................................................................................................................................................... 78 DRIVE SHAFT........................................................................................................................................................ 79 AXLE............................................................................................................................................................... 80 DIFFERENTIAL....................................................................................................................................................... 82 FINAL DRIVE........................................................................................................................................................ 86 AXLE MOUNT, CENTER HINGE PIN....................................................................................................................................... 87 STEERING PIPING.................................................................................................................................................... 88 STEERING COLUMN.................................................................................................................................................... 89 STEERING VALVE..................................................................................................................................................... 90 ORBIT-ROLL VALVE...................................................................................................................................................104 STOP VALVE.........................................................................................................................................................108 EMERGENCY STEERING PUMP............................................................................................................................................109 DIVERTER VALVE.....................................................................................................................................................110 BRAKE PIPING ......................................................................................................................................................113 BRAKE CIRCUIT DIAGRAM..............................................................................................................................................114 BRAKE VALVE........................................................................................................................................................116 CHARGE VALVE.......................................................................................................................................................121 ACCUMULATOR (FOR BRAKE)............................................................................................................................................127 SLACK ADJUSTER.....................................................................................................................................................128 BRAKE..............................................................................................................................................................131 PARKING BRAKE CONTROL..............................................................................................................................................133 PARKING BRAKE......................................................................................................................................................134 PARKING BRAKE SOLENOID VALVE.......................................................................................................................................135 PARKING BRAKE VALVE................................................................................................................................................136 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.....................................................................................................................137 HYDRAULIC PIPING...................................................................................................................................................138 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM............................................................................................................................139 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................................140 WORK EQUIPMENT LEVER LINKAGE.......................................................................................................................................142 HYDRAULIC TANK.....................................................................................................................................................143 PPC VALVE..........................................................................................................................................................145 PPC RELIEF VALVE...................................................................................................................................................150 ACCUMULATOR (FOR PPC VALVE)........................................................................................................................................151 MAIN CONTROL VALVE.................................................................................................................................................152 WORK EQUIPMENT LINKAGE.............................................................................................................................................165 BUCKET.............................................................................................................................................................167 BUCKET POSITIONED AND BOOM KICK-OUT................................................................................................................................168 CAB................................................................................................................................................................174 ROPS CAB...........................................................................................................................................................176 AIR CONDITIONER....................................................................................................................................................177 ELECTRIC CIRCUIT DIAGRAM...........................................................................................................................................178 MACHINE MONITOR SYSTEM.............................................................................................................................................189 MAIN MONITOR ......................................................................................................................................................190 MAINTENANCE MONITOR................................................................................................................................................195 WORK EQUIPMENT CONTROL SYSTEM......................................................................................................................................198 E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM).................................................................................................................205 SENSORS............................................................................................................................................................209 ENGINE STARTING CIRCUIT............................................................................................................................................214 ENGINE STOP CIRCUIT................................................................................................................................................215 PREHEATING CIRCUIT.................................................................................................................................................216 ELECTRIC TRANSMISSION CONTROL......................................................................................................................................217 KICK-DOWN SWITCH...................................................................................................................................................220 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.................................................................................................................................221 TRANSMISSION CUT-OFF SWITCH........................................................................................................................................226 TRANSMISSION CUT-OFF FUNCTION......................................................................................................................................227 ELECTRIC PARKING BRAKE CONTROL.....................................................................................................................................229 20 TESTING AND ADJUSTING...............................................................................................................................................241 STANDARD VALUE TABLE FOR ENGINE....................................................................................................................................242 STANDARD VALUE TABLE FOR CHASSIS...................................................................................................................................243 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..........................................................................................................................246 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..................................................................................................................251 ADJUSTING VALVE CLEARANCE..........................................................................................................................................252 MEASURING COMPRESSION PRESSURE.....................................................................................................................................253 TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................................................................................254 MEASURING EXHAUST COLOR............................................................................................................................................256 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).....................................................................................................................257 MEASURING BLOW-BY PRESSURE.........................................................................................................................................258 TESTING AND ADJUSTING FAN BELT TENSION.............................................................................................................................259 MEASURING ENGINE SPEED.............................................................................................................................................260 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE.......................................................................................................................261 MEASURING ENGINE OIL PRESSURE......................................................................................................................................263 MEASURING EXHAUST GAS TEMPERATURE..................................................................................................................................264 MEASURING ACCELERATOR PEDAL........................................................................................................................................265 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER...................................................................................................................267 MEASURING STALL SPEED..............................................................................................................................................268 MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE...............................................................................................270 METHOD OF OPERATING EMERGENCY MANUAL SPOOL.........................................................................................................................272 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL.........................................................................................................................274 TESTING AND ADJUSTING STEERING WHEEL...............................................................................................................................275 TESTING AND ADJUSTING STEERING CONTROL.............................................................................................................................278 MEASURING STEERING OIL PRESSURE....................................................................................................................................279 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL...................................................................................................................281 MEASURING BRAKE PERFORMANCE........................................................................................................................................282 TESTING BRAKE OIL PRESSURE.........................................................................................................................................283 TESTING FOR BRAKE DISC WEAR........................................................................................................................................284 BLEEDING AIR FROM BRAKE SYSTEM.....................................................................................................................................285 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE..................................................................................................................286 MEASURING PARKING BRAKE PERFORMANCE................................................................................................................................287 METHOD FOR MANUAL RELEASE OF PARKING BRAKE.........................................................................................................................288 TESTING WEAR OF PARKING BRAKE DISC.................................................................................................................................289 MEASURING WORK EQUIPMENT CONTROL LEVER.............................................................................................................................290 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE........................................................................................................................292 MEASURING WORK EQUIPMENT...........................................................................................................................................296 TESTING AND ADJUSTING BUCKET POSITIONER............................................................................................................................298 TESTING AND ADJUSTING BOOM KICK-OUT ...............................................................................................................................299 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)........................................................................................................................301 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR......................................................................................................................302 ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER.........................................................................................................................303 TROUBLESHOOTING....................................................................................................................................................304 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................................................305 SEQUENCE OF EVENTS IN TROUBLESHOOTING..........................................................................................................................306 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE......................................................................................................................307 HANDLING CONNECTORS............................................................................................................................................314 CHECKS BEFORE TROUBLESHOOTING..................................................................................................................................315 METHOD OF USING TROUBLESHOOTING CHARTS.........................................................................................................................316 CONNECTOR TYPES AND MOUNTING LOCATIONS.........................................................................................................................324 CONNECTOR PIN ARRANGEMENT DIAGRAM..............................................................................................................................325 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....................................................................................................................328 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)......................................................................................................................335 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..............................................................................................336 S-2 ENGINE DOES NOT START..................................................................................................................................337 (1) ENGINE DOES NOT TURN...............................................................................................................................337 (2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED).............................................................................338 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...........................................................................339 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...................................................................................................340 S-4 ENGINE STOPS DURING OPERATIONS.........................................................................................................................341 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..............................................................................................................342 S-6 ENGINE LACKS OUTPUT (NO POWER).........................................................................................................................343 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...........................................................................................................344 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..................................................................................................345 S-9 OIL BECOMES CONTAMINATED QUICKLY.......................................................................................................................346 S-10 FUEL CONSUMPTION IS EXCESSIVE.........................................................................................................................347 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...............................................................................348 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................................349 S-13 OIL LEVEL RISES.......................................................................................................................................350 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)......................................................................................................351 S-15 ABNORMAL NOISE IS MADE................................................................................................................................352 S-16 VIBRATION IS EXCESSIVE................................................................................................................................353 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)................................................................................................................354 TROUBLE DATA DISPLAY.......................................................................................................................................356 M-1 MAIN MONITOR DOES NOT WORK.............................................................................................................................359 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP.........................................................360 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.............................................................................................................361 M-4 ABNORMALITY IN SHIFT INDICATOR.........................................................................................................................362 (a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F.....................................................................................................362 (b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R.....................................................................................................362 (c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F...............................................362 (d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R...............................................363 (e) DOES NOT DISPLAY 1ST,4TH...........................................................................................................................363 (f) DOES NOT DISPLAY 3RD,4TH...........................................................................................................................364 (g) DOES NOT DISPLAY 2ND,3RD...........................................................................................................................364 (h) DOES NOT DISPLAY 1ST,2ND...........................................................................................................................365 M-5 HIGH BEAM DOES NOT LIGHT UP............................................................................................................................366 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP..................................................................................................................367 (a) L.H. TURN SIGNAL DOES NOT LIGHT UP.................................................................................................................367 (b) R.H. TURN SIGNAL DOES NOT LIGHT UP.................................................................................................................367 M-7 ABNORMALITY IN PARKING DISPLAY.........................................................................................................................368 (a) PARKING LAMP DOES NOT LIGHT UP.....................................................................................................................368 (b) PARKING LAMP STAYS LIGHTED UP......................................................................................................................368 M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS).................................................................................................................369 (a) DOES NOT CARRY OUT PREHEATING......................................................................................................................369 (b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE.........................................................................................................370 (c) PREHEATING STAYS ON................................................................................................................................370 (d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION.............................................................................................371 M-9 NIGHT LIGHTING DOES NOT LIGHT UP.......................................................................................................................372 M-10 ABNORMALITY IN FRONT WORKING LAMP.....................................................................................................................373 (a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP............................................................................................373 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................373 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...............................................................................................373 M-11 ABNORMALITY IN REAR WORKING LAMP......................................................................................................................374 (a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.............................................................................................374 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................374 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...............................................................................................374 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...................................................................................................................376 (a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN..........................................................376 (b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON.............................................................................................376 (c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED.....................................................................................377 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.........................................................................................................378 (a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES........................378 (b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N....378 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED.............................379 (a) ACTUATED CONTINUOUSLY..............................................................................................................................379 (b) NOT ACTUATED.......................................................................................................................................379 M-15 ABNORMALITY IN BUZZER.................................................................................................................................380 (a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)........................................................................380 (b) BUZZER ALWAYS SOUNDS...............................................................................................................................380 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY.................................................................................................381 M-17 ABNORMALITY IN FAILURE DISPLAY MODE...................................................................................................................382 (a) DOES NOT ENTER FAILURE DISPLAY MODE................................................................................................................382 (b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE.......................................................................382 M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY......................................................................................................383 (a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP................................................................................................383 (b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP.................................................................................................383 M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY...................................................................................................384 (a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP.............................................................................................384 (b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP..............................................................................................384 M-20 ABNORMALITY IN AUTO-GREASING SYSTEM...................................................................................................................385 (a) FORCED GREASING CANNOT BE CARRIED OUT..............................................................................................................385 (b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)......................................................................................................385 (c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC).........................................................................385 (d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)........................................................................................................386 (e) MONITOR DISPLAY GOES OUT...........................................................................................................................386 M-21 ABNORMALITY IN ECSS SYSTEM............................................................................................................................387 (a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED.....................................................................................................387 (b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK..........................................................................................387 M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED...........................................................................................387 M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK).....................................................................................388 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).........................................................................................................389 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK...................390 (a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS.....................................................................................390 (b) SOME LAMPS DO NOT LIGHT UP.........................................................................................................................391 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT.........................................................391 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT...............392 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH..................................................................................393 (a) ENGINE OIL LEVEL DISPLAY FLASHES...................................................................................................................393 (b) ENGINE WATER LEVEL DISPLAY FLASHES.................................................................................................................394 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH................................................................................395 (a) ENGINE OIL PRESSURE DISPLAY FLASHES................................................................................................................395 (b) BATTERY CHARGE LEVEL DISPLAY FLASHES...............................................................................................................396 (c) BRAKE OIL PRESSURE DISPLAY FLASHES.................................................................................................................397 (d) AIR CLEANER DISPLAY FLASHES........................................................................................................................398 K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND.............................................................................................399 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS.....................................................................................400 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP...............................................................401 (a) CHECK LAMP.........................................................................................................................................401 (b) CAUTION LAMP.......................................................................................................................................401 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP)LIGHTS UP............................................402 (a) CHECK LAMP.........................................................................................................................................402 (b) CAUTION LAMP.......................................................................................................................................402 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)...............................403 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP................................................................404 K-12 SERVICE METER DOES NOT WORK...........................................................................................................................405 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED..................................................................................................405 K-14 ABNORMALITY IN GAUGE ITEMS............................................................................................................................406 (a) ABNORMALITY IN FUEL GAUGE..........................................................................................................................406 (b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE......................................................................................................407 (c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE..............................................................................................408 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..................................................................................................................409 E-1 ENGINE DOES NOT START..................................................................................................................................410 (a) STARTING MOTOR DOES NOT TURN.......................................................................................................................410 (b) STARTING MOTOR TURNS...............................................................................................................................414 E-2 ENGINE DOES NOT STOP...................................................................................................................................416 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.................................................................................................................416 E-4 PARKING BRAKE DOES NOT WORK............................................................................................................................417 (a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON.................................................................................417 (b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS..............................................................................................417 E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.....................................................................................................418 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON ...........................................................................................420 E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED..................................................................................420 E-8 TRANSMISSION DOES NOT WORK NORMALLY....................................................................................................................421 (a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)...................................................................................423 (b) PROBLEM IN H-L CIRCUIT.............................................................................................................................423 (c) PROBLEM IN SPEED CIRCUIT...........................................................................................................................424 (d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)........................................................................................................424 (e) CONTACT IN H-L CIRCUIT.............................................................................................................................425 (f) CONTACT IN SPEED CIRCUIT...........................................................................................................................427 (g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH).......................................................................................................429 (h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL).....................................................................................................430 (i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL).....................................................................................................432 (j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL)...............................................434 (k) CONTACT IN FORWARD CIRCUIT.........................................................................................................................436 (l) CONTACT IN REVERSE CIRCUIT.........................................................................................................................438 (m) PROBLEM IN COMMON CIRCUIT FOE FORWARD AND REVERSE..................................................................................................440 E-9 KICK-DOWN SWITCH DOES NOT WORK.........................................................................................................................441 E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION) (SELF-HOLDING FUNCTION))..........................443 E-11 KICK-DOWN OPERATION CANNOT BE CANCELED................................................................................................................443 (a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R.................................................................................443 (b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH)...............................................................444 E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND.........................................................................................446 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)..................................................................................447 POWER TRAIN................................................................................................................................................448 T-1 MACHINE DOES NOT START.............................................................................................................................448 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES...............................................................................450 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.............................................................................................452 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR..........................................................................................453 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...........................................................................................................454 STEERING SYSTEM............................................................................................................................................455 T-6 STEERING DOES NOT TURN.............................................................................................................................455 T-7 STEERING WHEEL IS HEAVY............................................................................................................................456 T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK.................................................................................................457 T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING..........................................................................................................457 T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT.....................................................................................................457 BRAKE SYSTEM...............................................................................................................................................458 T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR......................................................................................................458 T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG............................................................................................................459 T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS......................................................................................................460 WORK EQUIPMENT.............................................................................................................................................461 T-14 BOOM DOES NOT RISE................................................................................................................................461 T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.................................................................................................462 T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT..........................................................................................463 T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)........................................................................................463 T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM.................................................................................................................463 T-19 BOOM SHAKES DURING OPERATION......................................................................................................................463 T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.........................................................................464 T-21 BUCKET DOES NOT TILT BACK.........................................................................................................................465 T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER..................................................................................................466 T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION...........................................................................................467 T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER......................................................................................................467 T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...............................................................................................................467 T-26 BUCKET SHAKES DURING LOADING OPERATION............................................................................................................468 T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.........................................................................468 T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY.....................................................................................469 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE).................................................................................470 JUDGMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM............................................................................................................471 D-1 ECSS DOES NOT WORK.....................................................................................................................................472 (a) ERROR CODE [d0] IS DISPLAYED.......................................................................................................................473 (b) ERROR CODE [d1] IS DISPLAYED.......................................................................................................................473 (c) ERROR CODE [d2] IS DISPLAYED.......................................................................................................................474 (d) ERROR CODE [d3] IS DISPLAYED.......................................................................................................................474 (e) ERROR CODE [d4] IS DISPLAYED.......................................................................................................................475 (f) NO ABNORMALITY DISPLAY IS GIVEN....................................................................................................................475 D-2 ECSS CANNOT BE CANCELED................................................................................................................................479 D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 km/h) (DEVIATES AROUND 5 km/h).....................................................................480 D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST........................................................................................................480 D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH........................................................................................................481 D-6 CONTROLLER LED CODE IS NOT DISPLAYED...................................................................................................................482 D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY....................................................................................482 TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)...................................................................................................483 OUTLINE....................................................................................................................................................485 1. FUNCTION............................................................................................................................................485 2. WHEN CARRYING OUT TROUBLESHOOTING...................................................................................................................485 3. FAILURE COED TABLE..................................................................................................................................485 4. TABLE OF TROUBLESHOOTING MODES AND CAUSES...........................................................................................................486 W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM...........................................................................................488 W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF...............................................................489 W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM...........................................................................................490 W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM...............................................................................................491 W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID.........................................................................492 W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID......................................................................492 W-7 FAILURE CODE [48] ABNORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM....................................................................................493 W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM......................................................................................495 W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM.............................................................................................496 W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH........................................................................497 W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIOMETER SYSTEM......................................................................................498 W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM....................................................................................498 W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS.......................................................................................500 W-14 SENSOR CANNOT BE ADJUSTED.............................................................................................................................501 W-15 DOES NOT CARRY OUT AUTO-LEVELING......................................................................................................................502 (a) AUTO-LEVELER SWITCH SYSTEM.........................................................................................................................502 (b) AUTO-LEVELER LED SYSTEM............................................................................................................................502 (c) BUCKET LEVER NEUTRAL SWITCH SYSTEM.................................................................................................................503 (d) ENGINE SPEED SIGNAL SYSTEM.........................................................................................................................504 W-16 AUTO-LEVELER CANNOT BE SET............................................................................................................................505 (a) AUTO-LEVELER SET SWITCH SYSTEM.....................................................................................................................505 (b) AUTO-LEVELER SET LED SYSTEM........................................................................................................................505 W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP...................................................................................................506 (a) REMOTE POSITIONED SWITCH SYSTEM....................................................................................................................506 (b) REMOTE POSITIONED LED SYSTEM.......................................................................................................................506 W-18 REMOTE POSITIONED SET LEDS DO NOT FLASH...............................................................................................................507 (a) REMOTE POSITIONED SWITCH SYSTEM....................................................................................................................507 (b) REMOTE POSITIONED LED SYSTEM.......................................................................................................................507 W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONED IS AT RAISE AND AUTO MODE IS ON .........................................508 W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND............................................................................................................509 W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW........................................................................................................510 W-22 BUCKET (LEVER) CONTROL................................................................................................................................511 (a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT..................................................................................511 (b) LEVER IS NOT HELD BY DETENT........................................................................................................................512 W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR.........................................................................................................514 W-24 MAINTENANCE MONITOR CHECK.............................................................................................................................515 30 DISASSEMBLY AND ASSEMBLY............................................................................................................................................516 METHOD OF USING MANUAL.............................................................................................................................................518 PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................................................519 SPECIAL TOOL LIST..................................................................................................................................................521 STARTING MOTOR.....................................................................................................................................................523 REMOVAL AND INSTALLATION.......................................................................................................................................523 ALTERNATOR.........................................................................................................................................................524 REMOVAL AND INSTALLATION.......................................................................................................................................524 ENGINE OIL COOLER..................................................................................................................................................525 REMOVAL AND INSTALLATION.......................................................................................................................................525 AFTERCOOLER CORE...................................................................................................................................................526 REMOVAL AND INSTALLATION.......................................................................................................................................526 FUEL INJECTION PUMP................................................................................................................................................527 REMOVAL........................................................................................................................................................527 INSTALLATION...................................................................................................................................................528 WATER PUMP.........................................................................................................................................................529 REMOVAL AND INSTALLATION.......................................................................................................................................529 TURBOCHARGER.......................................................................................................................................................530 REMOVAL AND INSTALLATION.......................................................................................................................................530 NOZZLE HOLDER......................................................................................................................................................531 REMOVAL AND INSTALLATION.......................................................................................................................................531 THERMOSTAT.........................................................................................................................................................532 REMOVAL AND INSTALLATION.......................................................................................................................................532 CYLINDER HEAD......................................................................................................................................................533 REMOVAL........................................................................................................................................................533 INSTALLATION...................................................................................................................................................539 RADIATOR...........................................................................................................................................................541 REMOVAL........................................................................................................................................................541 INSTALLATION...................................................................................................................................................543 ENGINE.............................................................................................................................................................544 REMOVAL........................................................................................................................................................544 INSTALLATION...................................................................................................................................................549 TORQUE CONVERTER CHARGING PUMP.....................................................................................................................................550 REMOVAL........................................................................................................................................................550 INSTALLATION...................................................................................................................................................550 TORQUE CONVERTER, TRANSMISSION.....................................................................................................................................551 REMOVAL........................................................................................................................................................551 INSTALLATION...................................................................................................................................................558 TORQUE CONVERTER...................................................................................................................................................560 DISASSEMBLY....................................................................................................................................................560 ASSEMBLY.......................................................................................................................................................562 TRANSMISSION.......................................................................................................................................................565 DISASSEMBLY....................................................................................................................................................565 ASSEMBLY.......................................................................................................................................................570 TRANSMISSION CLUTCH PACK...........................................................................................................................................576 DISASSEMBLY....................................................................................................................................................576 ASSEMBLY.......................................................................................................................................................585 PARKING BRAKE......................................................................................................................................................597 DISASSEMBLY....................................................................................................................................................597 ASSEMBLY.......................................................................................................................................................599 TRANSMISSION CONTROL VALVE.........................................................................................................................................602 REMOVAL........................................................................................................................................................602 INSTALLATION...................................................................................................................................................604 DISASSEMBLY....................................................................................................................................................605 ASSEMBLY.......................................................................................................................................................610 TRANSMISSION ACCUMULATOR VALVE.....................................................................................................................................616 DISASSEMBLY....................................................................................................................................................616 ASSEMBLY.......................................................................................................................................................617 DRIVE SHAFT........................................................................................................................................................618 DISASSEMBLY....................................................................................................................................................618 ASSEMBLY.......................................................................................................................................................620 FRONT AXLE.........................................................................................................................................................622 REMOVAL........................................................................................................................................................622 INSTALLATION...................................................................................................................................................624 REAR AXLE..........................................................................................................................................................625 REMOVAL........................................................................................................................................................625 INSTALLATION...................................................................................................................................................628 FRONT DIFFERENTIAL.................................................................................................................................................630 REMOVAL........................................................................................................................................................630 INSTALLATION...................................................................................................................................................633 REAR DIFFERENTIAL..................................................................................................................................................635 REMOVAL........................................................................................................................................................635 INSTALLATION...................................................................................................................................................638 DIFFERENTIAL.......................................................................................................................................................640 DISASSEMBLY....................................................................................................................................................640 ASSEMBLY.......................................................................................................................................................643 FINAL DRIVE........................................................................................................................................................651 DISASSEMBLY....................................................................................................................................................651 ASSEMBLY.......................................................................................................................................................654 CENTER HINGE PIN...................................................................................................................................................658 REMOVAL........................................................................................................................................................658 INSTALLATION...................................................................................................................................................666 STEERING VALVE.....................................................................................................................................................672 REMOVAL........................................................................................................................................................672 INSTALLATION...................................................................................................................................................673 DISASSEMBLY....................................................................................................................................................674 ASSEMBLY.......................................................................................................................................................677 STEERING VALVE.....................................................................................................................................................682 REMOVAL........................................................................................................................................................682 INSTALLATION...................................................................................................................................................683 STEERING DEMAND VALVE..............................................................................................................................................684 DISASSEMBLY....................................................................................................................................................684 ASSEMBLY.......................................................................................................................................................688 STEERING,SWITCH PUMP ..............................................................................................................................................692 REMOVAL........................................................................................................................................................692 INSTALLATION...................................................................................................................................................695 STEERING CYLINDER..................................................................................................................................................696 REMOVAL........................................................................................................................................................696 INSTALLATION...................................................................................................................................................697 BRAKE VALVE........................................................................................................................................................698 REMOVAL........................................................................................................................................................698 INSTALLATION...................................................................................................................................................699 RIGHT BRAKE VALVE (TANDEM).........................................................................................................................................700 DISASSEMBLY....................................................................................................................................................700 ASSEMBLY.......................................................................................................................................................701 LEFT BRAKE VALVE (SINGLE)..........................................................................................................................................702 DISASSEMBLY....................................................................................................................................................702 ASSEMBLY.......................................................................................................................................................703 SLACK ADJUSTER.....................................................................................................................................................704 REMOVAL........................................................................................................................................................704 INSTALLATION...................................................................................................................................................705 DISASSEMBLY....................................................................................................................................................706 ASSEMBLY.......................................................................................................................................................707 BRAKE..............................................................................................................................................................708 DISASSEMBLY....................................................................................................................................................708 ASSEMBLY.......................................................................................................................................................714 PARKING BRAKE DISC.................................................................................................................................................722 REMOVAL........................................................................................................................................................722 INSTALLATION...................................................................................................................................................724 ACCUMULATOR CHARGE VALVE...........................................................................................................................................725 REMOVAL AND INSTALLATION.......................................................................................................................................725 DISASSEMBLY....................................................................................................................................................726 ASSEMBLY.......................................................................................................................................................728 HYDRAULIC TANK.....................................................................................................................................................730 REMOVAL........................................................................................................................................................730 INSTALLATION...................................................................................................................................................732 WORK EQUIPMENT,PPC PUMP............................................................................................................................................733 REMOVAL........................................................................................................................................................733 INSTALLATION...................................................................................................................................................736 PPC VALVE..........................................................................................................................................................737 REMOVAL........................................................................................................................................................737 INSTALLATION...................................................................................................................................................738 DISASSEMBLY....................................................................................................................................................739 ASSEMBLY.......................................................................................................................................................740 MAIN CONTROL VALVE.................................................................................................................................................741 REMOVAL........................................................................................................................................................741 INSTALLATION...................................................................................................................................................743 DISASSEMBLY....................................................................................................................................................744 ASSEMBLY.......................................................................................................................................................746 BUCKET CYLINDER....................................................................................................................................................749 REMOVAL........................................................................................................................................................749 INSTALLATION...................................................................................................................................................750 BOOM CYLINDER......................................................................................................................................................751 REMOVAL........................................................................................................................................................751 INSTALLATION...................................................................................................................................................752 DISASSEMBLY....................................................................................................................................................753 ASSEMBLY.......................................................................................................................................................756 WORK EQUIPMENT.....................................................................................................................................................759 REMOVAL........................................................................................................................................................759 INSTALLATION...................................................................................................................................................762 COUNTERWEIGHT......................................................................................................................................................764 REMOVAL AND INSTALLATION.......................................................................................................................................764 FUEL TANK..........................................................................................................................................................765 REMOVAL........................................................................................................................................................765 INSTALLATION...................................................................................................................................................766 CAB................................................................................................................................................................767 REMOVAL........................................................................................................................................................767 INSTALLATION...................................................................................................................................................768 MAIN MONITOR.......................................................................................................................................................769 REMOVAL........................................................................................................................................................769 INSTALLATION...................................................................................................................................................770 MAINTENANCE MONITOR................................................................................................................................................771 REMOVAL AND INSTALLATION.......................................................................................................................................771 AIR CONDITIONER UNIT...............................................................................................................................................772 REMOVAL........................................................................................................................................................772 INSTALLATION...................................................................................................................................................777 AIR CONDITIONER CONDENSER..........................................................................................................................................778 REMOVAL........................................................................................................................................................778 INSTALLATION...................................................................................................................................................779 DRY RECEIVER.......................................................................................................................................................780 REMOVAL AND INSTALLATION.......................................................................................................................................780 AIR CONDITIONER CONDENSER COMPRESSOR...............................................................................................................................781 REMOVAL........................................................................................................................................................781 INSTALLATION...................................................................................................................................................782 40 MAINTENANCE STANDARD................................................................................................................................................783 ENGINE MOUNT, TRANSMISSION MOUNT...................................................................................................................................784 TORQUE CONVERTER...................................................................................................................................................785 TRANSMISSION.......................................................................................................................................................786 TRANSMISSION CONTROL VALVE.........................................................................................................................................793 DRIVE SHAFT........................................................................................................................................................797 DIFFERENTIAL.......................................................................................................................................................798 FINAL DRIVE........................................................................................................................................................800 AXLE MOUNT.........................................................................................................................................................801 STEERING COLUMN....................................................................................................................................................802 STEERING VALVE.....................................................................................................................................................803 STEERING CYLINDER MOUNT............................................................................................................................................804 SLACK ADJUSTER.....................................................................................................................................................805 BRAKE VALVE (SINGLE)...............................................................................................................................................806 BRAKE..............................................................................................................................................................809 PARKING BRAKE......................................................................................................................................................811 TORQUE CONVERTER,TRANSMISSION PUMP.................................................................................................................................812 STEERING,SWITCH PUMP...............................................................................................................................................813 HYDRAULIC,PPC PUMP.................................................................................................................................................814 PPC VALVE..........................................................................................................................................................815 CUT-OFF VALVE......................................................................................................................................................816 MAIN CONTROL VALVE.................................................................................................................................................817 HYDRAULIC CYLINDER.................................................................................................................................................821 CENTER HINGE PIN...................................................................................................................................................823 WORK EQUIPMENT LINKAGE.............................................................................................................................................825 BUCKET.............................................................................................................................................................827 BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................828
DESCRIPTION:
KOMATSU AVANCE LOADER WA420-3 SHOP MANUAL SEBM006204 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him 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.
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.
S.S 12/12/24
