Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) – PDF Download
Original price was: $67.95.$26.95Current price is: $26.95.
- KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30001 & UP
- PUBLICATION NUMBER:CEBM000200
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP)
KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP)
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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.
TABLE OF CONTENTS:
KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP)
MAIN MENU...................................................................................................................................................... 0 CONTENTS....................................................................................................................................................... 2 01 GENERAL..................................................................................................................................................... 20 SPECIFICATION DRAWINGS..................................................................................................................................... 21 SPECIFICATIONS ............................................................................................................................................ 22 WEIGHT TABLE .............................................................................................................................................. 25 FUEL, COOLANT AND LUBRICANTS .............................................................................................................................. 26 ENGINE OIL SPECIFICATIONS ................................................................................................................................. 27 DIESEL FUEL SPECIFICATIONS ................................................................................................................................ 28 COOLANT SPECIFICATIONS .................................................................................................................................... 29 10 STRUCTURE AND FUNCTION...................................................................................................................................... 34 POWER TRAIN................................................................................................................................................ 35 POWER TRAIN SYSTEM......................................................................................................................................... 36 TORQUE CONVERTER, TRANSMISSION PIPING .................................................................................................................... 38 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM ..................................................................................................................... 39 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM .................................................................................................................... 40 TORQUE CONVERTER .......................................................................................................................................... 41 TORQUE CONVERTER OIL FILTER ............................................................................................................................... 44 TRANSMISSION............................................................................................................................................... 45 TRANSMISSION CONTROL VALVE................................................................................................................................. 55 MODULATION VALVE........................................................................................................................................... 68 TRANSMISSION SOLENOID VALVE................................................................................................................................ 68 ELECTRONIC CONTROL MODULATION VALVE (ECMV)................................................................................................................. 69 PILOT OIL FILTER .......................................................................................................................................... 72 DRIVE SHAFT ............................................................................................................................................... 73 AXLE ...................................................................................................................................................... 74 DIFFERENTIAL .............................................................................................................................................. 76 FINAL DRIVE ............................................................................................................................................... 80 AXLE MOUNT, CENTER HINGE PIN .............................................................................................................................. 81 STEERING PIPING ........................................................................................................................................... 82 STEERING COLUMN ........................................................................................................................................... 83 STEERING VALVE ............................................................................................................................................ 84 STEERING VALVE (ORBIT-ROLL)................................................................................................................................ 98 STOP VALVE ................................................................................................................................................102 EMERGENCY STEERING PUMP ...................................................................................................................................103 DIVERTER VALVE ............................................................................................................................................104 BRAKE PIPING...............................................................................................................................................107 BRAKE CIRCUIT DIAGRAM .....................................................................................................................................108 BRAKE VALVE ...............................................................................................................................................109 ACCUMLATOR CHARGE VALVE ...................................................................................................................................114 ACCUMULATOR (FOR BRAKE) ..................................................................................................................................118 SLACK ADJUSTER ............................................................................................................................................119 BRAKE......................................................................................................................................................122 PARKING BRAKE CONTROL .....................................................................................................................................124 PARKING BRAKE .............................................................................................................................................125 PARKING BRAKE SOLENOID VALVE ..............................................................................................................................126 PARKING BRAKE VALVE .......................................................................................................................................127 PARKING EMERGENCY RELEASE SOLENOID VALVE ..................................................................................................................128 HYDRAULIC PIPING...........................................................................................................................................129 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....................................................................................................................130 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................131 WORK EQUIPMENT LEVER LINKAGE...............................................................................................................................132 HYDRAULIC TANK ............................................................................................................................................133 PPC VALVE .................................................................................................................................................135 PPC RELIEF VALVE ..........................................................................................................................................140 ACCUMULATOR (FOR PPC VALVE) ..............................................................................................................................141 MAIN CONTROL VALVE ........................................................................................................................................142 WORK EQUIPMENT LINKAGE ....................................................................................................................................155 BUCKET ....................................................................................................................................................157 BUCKET POSITIONER AND BOOM KICK-OUT .......................................................................................................................158 CAB .......................................................................................................................................................164 AIR CONDITIONER ...........................................................................................................................................165 ELECTRIC CIRCUIT DIAGRAM...................................................................................................................................166 WIRING DIAGRAM (EAGLE AIR CONDITIONER/HEATER)..............................................................................................................170 ELECTRIC CIRCUIT DIAGRAM (E.C.S.S.)........................................................................................................................171 ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING)...................................................................................................................172 MACHINE MONITOR SYSTEM.....................................................................................................................................173 MAIN MONITOR...............................................................................................................................................174 MAINTENANCE MONITOR........................................................................................................................................178 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM.....................................................................................................................180 TRANSMISSION CONTROLLER....................................................................................................................................185 E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM).........................................................................................................186 SENSORS....................................................................................................................................................190 ENGINE STARTING CIRCUIT....................................................................................................................................195 ENGINE STARTING CIRCUIT (ETHER START)......................................................................................................................196 ELECTRIC TRANSMISSION CONTROL..............................................................................................................................197 KICK-DOWN, HOLD SWITCH.....................................................................................................................................200 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.........................................................................................................................201 TRANSMISSION CUT-OFF SWITCH................................................................................................................................205 TRANSMISSION CUT-OFF FUNCTION..............................................................................................................................206 ELECTRIC PARKING BRAKE CONTROL ............................................................................................................................208 20 TESTING AND ADJUSTING.......................................................................................................................................220 STANDARD VALUE TABLE FOR ENGINE ...........................................................................................................................221 STANDARD VALUE TABLE FOR CHASSIS ..........................................................................................................................222 STANDARD VALUE TABLE FOR ELECTRICAL PARTS .................................................................................................................225 TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING ............................................................................................................229 MEASURING ENGINE SPEED ....................................................................................................................................232 MEASURING INTAKE MANIFOLD PRESSURE ........................................................................................................................233 MEASURING INTAKE AIR RESTRICTION ..........................................................................................................................234 MEASURING ENGINE LUBRICATING OIL PRESSURE .................................................................................................................235 MEASURING FUEL FILTER INLET RESTRICTION....................................................................................................................236 MEASURING BLOW-BY PRESSURE.................................................................................................................................237 MEASURING EXHAUST BACK PRESSURE ..........................................................................................................................238 MEASURING COOLANT TEMPERATURE..............................................................................................................................239 MEASURING AND ADJUSTING VALVE CLEARANCE ...................................................................................................................240 MEASURING WASTEGATE ACTUATOR CALIBRATION ..................................................................................................................241 MEASURING EXAUST COLOR ....................................................................................................................................242 MEASURING ACCELERATOR PEDAL ..............................................................................................................................243 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER ..........................................................................................................245 MEASURING STALL SPEEDS ....................................................................................................................................246 MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE.......................................................................................248 METHOD OF OPERATING EMERGENCY MANUAL SPOOL ................................................................................................................250 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL ................................................................................................................252 TESTING AND ADJUSTING STEERING WHEEL .....................................................................................................................253 TESTING AND ADJUSTING STEERING CONTROL.....................................................................................................................256 MEASURING STEERING OIL PRESSURE ...........................................................................................................................257 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL ..........................................................................................................259 MEASURING BRAKE PERFORMANCE ...............................................................................................................................260 TESTING BRAKE OIL PRESSURE ................................................................................................................................261 MEASURING BRAKE DISC WEAR .................................................................................................................................262 BLEEDING AIR FROM BRAKE SYSTEM ............................................................................................................................263 MEASURING PARKING BRAKE PERFORMANCE .......................................................................................................................264 MANUAL RELEASE METHOD FOR PARKING BRAKE ...................................................................................................................265 TESTING WEAR OF PARKING BRAKE DISC ........................................................................................................................266 MEASURING WORK EQUIPMENT CONTROL LEVER ....................................................................................................................267 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE ...............................................................................................................269 MEASURING WORK EQUIPMENT ..................................................................................................................................273 TESTING AND ADJUSTING BUCKET POSITIONER....................................................................................................................275 TESTING AND ADJUSTING BOOM KICK-OUT .......................................................................................................................276 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)................................................................................................................278 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR .............................................................................................................279 TROUBLESHOOTING............................................................................................................................................280 POINTS TO REMEMBER WHEN TROUBLESHOOTING ...............................................................................................................281 SEQUENCE OF EVENTS IN TROUBLESHOOTING .................................................................................................................282 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE .............................................................................................................283 HANDLING CONNECTORS ...................................................................................................................................290 CHECKS BEFORE TROUBLESHOOTING .........................................................................................................................291 METHOD OF USING TROUBLESHOOTING CHARTS ................................................................................................................292 CONNECTOR TYPES AND MOUNTING LOCATIONS, CONNECTOR PIN ARRANGEMENT DIAGRAM .............................................................................300 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................................304 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..............................................................................................................311 S-1 Starting performance is poor (Starting always takes time) .....................................................................................312 S-2 Engine does not start .........................................................................................................................313 (I) Engine does not turn.......................................................................................................................313 (2) Engine turns but no exhaust gas comes out (Fuel is not being injected).....................................................................314 (3) Exhaust gas comes out but engine does not start (Fuel is being injected)...................................................................315 S-3 Engine does not pick up smoothly (Follow-up is poor) ..........................................................................................316 S-4 Engine stops during operations ................................................................................................................317 S-5 Engine does not rotate smoothly (hunting) .....................................................................................................318 S-6 Engine lacks output (no power) ................................................................................................................319 S-7 Exhaust gas is black (incomplete combustion) ..................................................................................................320 S-8 Oil consumption is excessive (or exhaust gas is blue)..........................................................................................321 S-9 Oil becomes contaminated quickly ..............................................................................................................322 S-10 Fuel consumption is excessive ................................................................................................................323 S-11 Oil is in cooling water, or water spurts back, or water level goes down .....................................................................324 S-12 Oil pressure lamp lights up (drop in oil pressure) ...........................................................................................325 S-13 Oil level rises ..............................................................................................................................326 S-14 Water temperature becomes too high (overheating) ............................................................................................327 S-15 Abnormal noise is made .......................................................................................................................328 S-16 Vibration is excessive .......................................................................................................................329 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)........................................................................................................330 TROUBLE DATA DISPLAY ..............................................................................................................................332 M-1 Main monitor does not work ....................................................................................................................335 M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up ...............................................336 M-3 Speedometer display does not work properly ....................................................................................................337 M-4 Abnormality in shift indicator ................................................................................................................338 (a) Stays at N even when directional lever is at F.............................................................................................338 (b) Stays at N even when directional lever is at R.............................................................................................338 (c) Does not display N even when directional lever is at N and displays R when directional lever is at F.......................................338 (d) Does not display N even when directional lever is at N and displays F when directional lever is at R.......................................339 (e) Does not display 1st, 4th..................................................................................................................339 (f) Does not display 3rd, 4th..................................................................................................................340 (g) Does not display 2nd, 3rd..................................................................................................................340 (h) Does not display 1st, 2nd..................................................................................................................341 M-5 High beam does not light up ...................................................................................................................342 M-6 Turn signal display does not light up .........................................................................................................343 (a) L.H. turn signal does not light up.........................................................................................................343 (b) R.H. turn signal does not light up.........................................................................................................343 M-7 Abnormality in parking display ................................................................................................................344 (a) Parking lamp does not light up.............................................................................................................344 (b) Parking lamp stays lighted up..............................................................................................................344 M-8 Abnormality in preheating system (QGS) ........................................................................................................345 (a) Does not carry out preheating..............................................................................................................345 (b) Always carries out preheating for 1 minute.................................................................................................346 (c) Preheating stays on........................................................................................................................346 (d) Preheating time becomes shorter, or there is variation.....................................................................................347 M-9 Night lighting does not light up ..............................................................................................................348 M-10 Abnormality in front working lamp ............................................................................................................349 (a) Neither monitor display nor front working lamp light up....................................................................................349 (b) Working lamp lights up but monitor display does not light up...............................................................................349 (c) Monitor lights up but working lamp does not light up.......................................................................................349 M-11 Abnormality in rear working lamp .............................................................................................................350 (a) Neither monitor display nor rear working lamp light up.....................................................................................350 (b) Working lamp lights up but monitor display does not light up...............................................................................350 (c) Monitor lights up but working lamp does not light up.......................................................................................350 M-12 Abnormality in transmission cut-off ..........................................................................................................352 (a) When monitor switch is pressed, cut-off function is not switched and display is not given..................................................352 (b) Monitor display goes out but cut-off function stays on.....................................................................................352 (c) Monitor display lights up but cut-off function is not actuated.............................................................................353 M-13 Abnormality in parking brake dragging warning ................................................................................................354 (a) When parking brake is applied, buzzer sounds (intermittently) even when directional lever is at N, caution lamp flashes....................354 (b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at..................354 M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated ...................355 (a) Actuated continuously......................................................................................................................355 (b) Not actuated...............................................................................................................................355 M-15 Abnormality in buzzer ........................................................................................................................356 (a) Buzzer does not sound when starting switch is turned ON (during self-check)................................................................356 (b) Buzzer always sounds.......................................................................................................................356 M-16 Condition of monitor switches is not stored in memory ........................................................................................357 M-17 Abnormality in failure display mode ..........................................................................................................358 (a) Does not enter failure display mode........................................................................................................358 (b) Time for time elapsed since failure on failure display mode does not advance...............................................................358 M-18 Abnormality in emergency steering normal display .............................................................................................359 (a) Emergency steering normal display does not light up........................................................................................359 (b) Emergency steering normal display stays lighted up.........................................................................................359 M-19 Abnormality in emergency steering actuation display ..........................................................................................360 (a) Emergency steering actuation display does not light up.....................................................................................360 (b) Emergency steering actuation display stays lighted up......................................................................................360 M-20 Abnormality in auto-greasing system ..........................................................................................................361 (a) Forced greasing cannot be carried out......................................................................................................361 (b) Monitor display flashes rapidly (2 times/sec)..............................................................................................361 (c) When no more grease remains, monitor display flashes rapidly (2 times/sec).................................................................361 (d) Monitor display flashes slowly (1 time/sec)................................................................................................362 (e) Monitor display goes out...................................................................................................................362 M-21 Abnormality in ECSS system ...................................................................................................................363 (a) Display does not change when switch is pressed.............................................................................................363 (b) Monitor display lights up but ECSS function does not work..................................................................................363 M-22 Buzzer does not sound when auto-leveling switch is actuated .................................................................................363 M-23 Failure code is not sent to main monitor (abnormality in network) ...........................................................................364 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).................................................................................................365 K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec, and does not work ..............................366 (a) All lamps on maintenance monitor do not light up for 3 seconds.............................................................................366 (b) Some lamps do not light up.................................................................................................................367 K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out ...............................................367 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 ....368 K-4 When starting switch is turned ON (engine stopped), CHECK items flash ........................................................................369 (a) Engine oil level display flashes...........................................................................................................369 (b) Engine water level display flashes.........................................................................................................370 K-5 When starting switch is turned ON (engine started), CAUTION items flash ......................................................................371 (a) Engine oil pressure display flashes........................................................................................................371 (b) Battery charge level display flashes.......................................................................................................372 (c) Brake oil pressure display flashes.........................................................................................................373 (d) Air cleaner display flashes................................................................................................................374 K-6 CAUTION items are flashing but alarm buzzer does not sound ....................................................................................375 K-7 There is no abnormality in monitor display but alarm buzzer sounds ...........................................................................376 K-8 CAUTION items are flashing but warning lamp (CHECK CAUTION lamp) does not light up ...........................................................377 (a) CHECK lamp.................................................................................................................................377 (b) CAUTION lamp...............................................................................................................................377 K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up .................................378 (a) CHECK lamp.................................................................................................................................378 (b) CAUTION lamp...............................................................................................................................378 K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) .....................379 K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up ......................................................380 K-12 Service meter does not work ..................................................................................................................381 K-13 Service meter is running even when engine is stopped..........................................................................................381 K-14 Abnormality in gauge items ...................................................................................................................382 (a) Abnormality in fuel gauge..................................................................................................................382 (b) Abnormality in engine water temperature gauge..............................................................................................383 (c) Abnormality in torque converter oil temperature gauge......................................................................................384 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..........................................................................................................385 E-1 Engine does not start .........................................................................................................................386 (a) Starting motor does not turn...............................................................................................................386 (b) Starting motor turns.......................................................................................................................390 E-2 Engine does not stop ..........................................................................................................................392 E-3 Engine stops when machine is traveling ........................................................................................................392 E-4 Parking brake does not work ...................................................................................................................393 (a) Parking brake has no effect when parking brake switch is turned ON (parking)...............................................................393 (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)...................................................393 E-5 Parking brake is applied when machine is traveling ............................................................................................394 E-6 Parking brake is released when starting switch is turned ON ...................................................................................396 E-7 Transmission does not change to neutral when parking brake is applied (but parking brake works normally) ....................................396 E-8 Transmission does not work normally ...........................................................................................................397 (a) Problem in common circuit for transmission (always stays in 2nd)...........................................................................399 (b) Problem in H-L circuit.....................................................................................................................399 (c) Problem in speed circuit...................................................................................................................400 (d) Problem in 4th circuit (does not enter 4th)................................................................................................400 (e) Contact in H-L circuit.....................................................................................................................401 (f) Contact in speed circuit...................................................................................................................403 (g) Contact in 4th circuit (always stays in 4th)...............................................................................................405 (h) Problem in FORWARD circuit (REVERSE is normal).............................................................................................406 (i) Problem in REVERSE circuit (FORWARD is normal).............................................................................................408 (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal).......................................410 (k) Contact in FORWARD circuit.................................................................................................................412 (l) Contact in REVERSE circuit.................................................................................................................414 (m) Problem in common circuit for FORWARD and REVERSE..........................................................................................416 E-9 Kick-down switch does not work (the regular Fl to F4 shifts normally).........................................................................417 E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position............................................419 E-11 Kick-down operation cannot be canceled .......................................................................................................419 (a) Not canceled even when directional lever is moved from F to N or R.........................................................................419 (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th).......................................................420 E-12 Kick-down switch is actuated by mistake when traveling in 2nd ................................................................................422 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)..........................................................................423 POWER TRAIN .......................................................................................................................................424 T-1 Machine does not start ....................................................................................................................424 T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes .....................................................................426 T-3 Excessive shock when starting machine or shifting gear ....................................................................................428 T-4 Excessive time lag when starting machine or shifting gear .................................................................................429 T-5 Torque converter oil temperature is high ..................................................................................................430 STEERING SYSTEM ...................................................................................................................................431 T-6 Steering does not turn ....................................................................................................................431 T-7 Steering wheel is heavy ...................................................................................................................432 T-8 Steering wheel wobbles or there is excessive shock .......................................................................................433 T-9 Machine steers to one side when traveling ................................................................................................433 T-10 Turning radius to left and right is different ...........................................................................................433 BRAKE SYSTEM ......................................................................................................................................434 T-11 Brakes do not work or braking effect is poor .............................................................................................434 T-12 Brakes are not released or brakes drag ...................................................................................................435 T-13 Parking brake is not released or brake drags .............................................................................................436 WORK EQUIPMENT ....................................................................................................................................437 T-14 Boom does not rise .......................................................................................................................437 T-15 Boom movement is slow or boom lacks lifting power ........................................................................................438 T-16 When boom is raised, it moves slowly at a certain height .................................................................................439 T-17 Bucket cannot be pushed with boom cylinder (bucket floats) ...............................................................................439 T-18 Excessive hydraulic drift of boom ........................................................................................................439 T-19 Boom shakes during operation .............................................................................................................439 T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE ................................................................440 T-21 Bucket does not tilt back ................................................................................................................441 T-22 Bucket movement is slow or tilt-back lacks power .........................................................................................442 T-23 Bucket movement becomes slow during tilt-back operation ..................................................................................443 T-24 Bucket cannot be pushed with bucket cylinder .............................................................................................443 T-25 Excessive hydraulic drift of bucket ......................................................................................................443 T-26 Bucket shakes during loading operation (Main control valve at HOLD) .....................................................................444 T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT ...............................................................444 T-28 Boom, bucket control levers are heavy or do not move smoothly ............................................................................445 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE).........................................................................446 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM ..................................................................................................447 D-1 ECSS does not work ............................................................................................................................448 (a) Error code [d0] is displayed...............................................................................................................449 (b) Error code [d1] is displayed...............................................................................................................449 (c) Error code [d2] is displayed...............................................................................................................450 (d) Error code [d3] is displayed...............................................................................................................450 (e) Error code [d4] is displayed...............................................................................................................451 (f) No abnormality display is given............................................................................................................451 D-2 ECSS canceled .................................................................................................................................455 D-3 Output is turned ON (travel speed does not become 5 km/h) (deviates around 5 km/h) ...........................................................456 D-4 Output is turned ON when transmission z is in 1st 4 ........................................................................................456 D-5 Output is turned ON when transmission is in 4th ...............................................................................................457 D-6 Controller LED code is not displayed ..........................................................................................................458 D-7 ECSS is abnormal but main monitor does not give abnormality display ..........................................................................458 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE).............................................................................................459 OUTLINE............................................................................................................................................460 1. Function........................................................................................................................................460 2. When carrying out troubleshooting...............................................................................................................460 3. Failure code table..............................................................................................................................460 4. Table of troubleshooting modes and causes.......................................................................................................461 A-1 Troubleshooting code [10] Modulation valve solenoid system (disconnection, short circuit) ....................................................462 A-2 Troubleshooting code [11] Short circuit in power source for modulation valve solenoid system ..................................................463 A-3 Troubleshooting code [12] F solenoid signal system ............................................................................................464 A-4 Troubleshooting code [13] R solenoid signal system ............................................................................................464 A-5 Troubleshooting code [14] Abnormality in H-L solenoid signal system ..........................................................................465 A-6 Troubleshooting code [16] Abnormality in speed solenoid signal system ........................................................................466 A-7 Troubleshooting code [17] Brake output signal..................................................................................................467 A-8 Troubleshooting code [20] Abnormality in directional lever signal system .....................................................................468 A-9 Troubleshooting code [21] Abnormality in speed lever signal system ...........................................................................469 A-10 Troubleshooting code [22] Abnormality in travel speed signal .................................................................................470 A-11 Troubleshooting code [23] Abnormality in engine speed signal..................................................................................471 A-12 Hold switch system............................................................................................................................472 A-13 Kick-down switch..............................................................................................................................472 A-14 Kick-down output signal system ...............................................................................................................473 A-15 Transmission cut-off signal system ...........................................................................................................474 A-l 6 Neutralizer signal system ...................................................................................................................475 A-17 Buzzer signal system .........................................................................................................................476 A-18 Network signal system ........................................................................................................................477 A-19 Controller power source system ...............................................................................................................478 A-20 Abnormality in model selection wiring harness ................................................................................................479 TROUBLESHOOTING - EAGLE AIR CONDITIONER ...............................................................................................................480 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................................484 METHOD OF USING MANUAL ....................................................................................................................................486 PRECAUTIONS WHEN CARRYING OUT OPERATION ...................................................................................................................487 SPECIAL TOOL LIST .........................................................................................................................................489 RADIATOR...................................................................................................................................................492 REMOVAL ...............................................................................................................................................492 INSTALLATION ..........................................................................................................................................494 ENGINE.....................................................................................................................................................495 REMOVAL ...............................................................................................................................................495 INSTALLATION ..........................................................................................................................................500 TORQUE CONVERTER CHARGING PUMP.............................................................................................................................501 REMOVAL ...............................................................................................................................................501 INSTALLATION ..........................................................................................................................................501 TORQUE CONVERTER, TRANSMISSION.............................................................................................................................502 REMOVAL ...............................................................................................................................................502 INSTALLATION ..........................................................................................................................................509 TORQUE CONVERTER...........................................................................................................................................511 DISASSEMBLY ...........................................................................................................................................511 ASSEMBLY ..............................................................................................................................................513 TRANSMISSION...............................................................................................................................................516 DISASSEMBLY ...........................................................................................................................................516 ASSEMBLY ..............................................................................................................................................521 TRANSMISSION CLUTCH PACK...................................................................................................................................527 DISASSEMBLY............................................................................................................................................527 ASSEMBLY ..............................................................................................................................................536 PARKING BRAKE..............................................................................................................................................548 DISASSEMBLY ...........................................................................................................................................548 ASSEMBLY ..............................................................................................................................................550 TRANSMISSION CONTROL VALVE.................................................................................................................................553 REMOVAL................................................................................................................................................553 INSTALLATION...........................................................................................................................................555 DISASSEMBLY............................................................................................................................................556 ASSEMBLY...............................................................................................................................................563 TRANSMISSION ACCUMULATOR VALVE.............................................................................................................................569 DISASSEMBLY ...........................................................................................................................................569 ASSEMBLY ..............................................................................................................................................570 DRIVE SHAFT................................................................................................................................................571 DISASSEMBLY ...........................................................................................................................................571 ASSEMBLY ..............................................................................................................................................573 FRONT AXLE.................................................................................................................................................575 REMOVAL................................................................................................................................................575 INSTALLATION ..........................................................................................................................................577 REAR AXLE..................................................................................................................................................578 REMOVAL................................................................................................................................................578 INSTALLATION ..........................................................................................................................................581 FRONT DIFFERENTIAL.........................................................................................................................................583 REMOVAL ...............................................................................................................................................583 INSTALLATION ..........................................................................................................................................586 REAR DIFFERENTIAL..........................................................................................................................................588 REMOVAL ...............................................................................................................................................588 INSTALLATION...........................................................................................................................................591 DIFFERENTIAL...............................................................................................................................................593 DISASSEMBLY ...........................................................................................................................................593 ASSEMBLY ..............................................................................................................................................596 FINAL DRIVE................................................................................................................................................604 DISASSEMBLY ...........................................................................................................................................604 ASSEMBLY ..............................................................................................................................................607 CENTER HINGE PIN...........................................................................................................................................611 REMOVAL ...............................................................................................................................................611 INSTALLATION ..........................................................................................................................................619 STEERING VALVE (ORBIT-ROLL)................................................................................................................................625 REMOVAL ...............................................................................................................................................625 INSTALLATION...........................................................................................................................................626 STEERING VALVE.............................................................................................................................................627 DISASSEMBLY............................................................................................................................................627 ASSEMBLY...............................................................................................................................................630 REMOVAL................................................................................................................................................635 INSTALLATION ..........................................................................................................................................636 STEERING DEMAND VALVE......................................................................................................................................637 DISASSEMBLY ...........................................................................................................................................637 ASSEMBLY ..............................................................................................................................................641 STEERING SWITCH PUMP.......................................................................................................................................645 REMOVAL ...............................................................................................................................................645 INSTALLATION ..........................................................................................................................................648 STEERING CYLINDER..........................................................................................................................................649 REMOVAL ...............................................................................................................................................649 INSTALLATION...........................................................................................................................................650 BRAKE VALVE................................................................................................................................................651 REMOVAL ...............................................................................................................................................651 INSTALLATION ..........................................................................................................................................652 RIGHT BRAKE VALVE (TANDEM).................................................................................................................................653 DISASSEMBLY ...........................................................................................................................................653 ASSEMBLY...............................................................................................................................................654 LEFT BRAKE VALVE (SINGLE)..................................................................................................................................655 DISASSEMBLY ...........................................................................................................................................655 ASSEMBLY ..............................................................................................................................................656 SLACK ADJUSTER.............................................................................................................................................657 REMOVAL ...............................................................................................................................................657 INSTALLATION...........................................................................................................................................658 DISASSEMBLY ...........................................................................................................................................659 ASSEMBLY...............................................................................................................................................660 BRAKE ASSEMBLY.............................................................................................................................................661 DISASSEMBLY ...........................................................................................................................................661 ASSEMBLY...............................................................................................................................................667 PARKING BRAKE DISC.........................................................................................................................................675 REMOVAL................................................................................................................................................675 INSTALLATION ..........................................................................................................................................677 HYDRAULIC TANK.............................................................................................................................................680 REMOVAL ...............................................................................................................................................681 INSTALLATION ..........................................................................................................................................680 WORK EQUIPMENT, PPC PUMP...................................................................................................................................681 REMOVAL................................................................................................................................................681 INSTALLATION ..........................................................................................................................................684 PPC VALVE..................................................................................................................................................685 REMOVAL ...............................................................................................................................................685 INSTALLATION ..........................................................................................................................................686 DISASSEMBLY ...........................................................................................................................................687 ASSEMBLY...............................................................................................................................................688 MAIN CONTROL VALVE.........................................................................................................................................689 REMOVAL ...............................................................................................................................................689 INSTALLATION ..........................................................................................................................................691 DISASSEMBLY............................................................................................................................................692 ASSEMBLY ..............................................................................................................................................694 BUCKET CYLINDER............................................................................................................................................697 REMOVAL ...............................................................................................................................................697 INSTALLATION ..........................................................................................................................................698 BOOM CYLINDER..............................................................................................................................................699 REMOVAL................................................................................................................................................699 INSTALLATION ..........................................................................................................................................700 HYDRAULIC CYLINDER.........................................................................................................................................701 DISASSEMBLY ...........................................................................................................................................701 ASSEMBLY ..............................................................................................................................................704 WORK EQUIPMENT.............................................................................................................................................707 REMOVAL ...............................................................................................................................................707 INSTALLATION ..........................................................................................................................................710 COUNTERWEIGHT..............................................................................................................................................712 REMOVAL ...............................................................................................................................................712 INSTALLATION...........................................................................................................................................712 FUEL TANK..................................................................................................................................................713 REMOVAL ...............................................................................................................................................713 INSTALLATION...........................................................................................................................................714 CAB........................................................................................................................................................715 REMOVAL ...............................................................................................................................................715 INSTALLATION .........................................................................................................................................716 MAIN MONITOR...............................................................................................................................................717 REMOVAL ...............................................................................................................................................717 INSTALLATION ..........................................................................................................................................718 MAINTENANCE MONITOR........................................................................................................................................719 REMOVAL ...............................................................................................................................................719 INSTALLATION ..........................................................................................................................................719 AIR CONDITIONER UNIT.......................................................................................................................................720 REMOVAL................................................................................................................................................720 INSTALLATION ..........................................................................................................................................725 AIR CONDITIONER CONDENSER..................................................................................................................................726 REMOVAL ...............................................................................................................................................726 INSTALLATION...........................................................................................................................................727 DRY RECEIVER...............................................................................................................................................728 REMOVAL ...............................................................................................................................................728 INSTALLATION ..........................................................................................................................................728 AIR CONDITIONER COMPRESSOR.................................................................................................................................729 REMOVAL ...............................................................................................................................................729 INSTALLATION...........................................................................................................................................730 40 MAINTENANCE STANDARD........................................................................................................................................731 ENGINE MOUNT, TRANSMISSION MOUNT ..........................................................................................................................732 TORQUE CONVERTER ..........................................................................................................................................733 TRANSMISSION ..............................................................................................................................................734 TRANSMISSION CONTROL VALVE ................................................................................................................................741 DRIVE SHAFT ...............................................................................................................................................745 DIFFERENTIAL ..............................................................................................................................................746 FINAL DRIVE ...............................................................................................................................................748 AXLE MOUNT ................................................................................................................................................749 STEERING COLUMN ...........................................................................................................................................750 STEERING VALVE ............................................................................................................................................751 STEERING CYLINDER MOUNT ...................................................................................................................................752 SLACK ADJUSTER ............................................................................................................................................753 BRAKE VALVE................................................................................................................................................754 BRAKE .....................................................................................................................................................757 PARKING BRAKE .............................................................................................................................................759 TORQUE CONVERTER, TRANSMISSION PUMP .......................................................................................................................760 STEERING SWITCH PUMP....................................................................................................................................... 0 HYDRAULIC PPC PUMP......................................................................................................................................... 0 PPC VALVE .................................................................................................................................................761 CUT-OFF VALVE .............................................................................................................................................762 MAIN CONTROL VALVE ........................................................................................................................................763 HYDRAULIC CYLINDER ........................................................................................................................................767 CENTER HINGE PIN ..........................................................................................................................................769 WORK EQUIPMENT LINKAGE ....................................................................................................................................771 BUCKET ....................................................................................................................................................773 BUCKET POSITIONER AND BOOM KICK-OUT .......................................................................................................................774
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
1 review for KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) – PDF Download
Add a review
Leandro Raiden –