KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:WA420H20051 and up) KOMATSU WA420 3 – PDF DOWNLOAD

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KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:WA420H20051 and up) KOMATSU WA420 3

KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:WA420H20051 AND UP) KOMATSU WA420 3 – PDF DOWNLOAD:

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KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:WA420H20051 and up) KOMATSU WA420 3

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel an accurate understanding of the product and by showing them 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

TABLE OF CONTENTS:

KOMATSU WA420-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:WA420H20051 and up) KOMATSU WA420 3

COVER.................................................................................  1
Contents..............................................................................  2
01 General............................................................................  9
	Up to SN WA420H30296.............................................................. 10
	Dimensions and weights............................................................ 10
	Specifications.................................................................... 12
	Weight table...................................................................... 15
	SN WA420H30297 and up............................................................. 17
	Dimensions and weights............................................................ 17
	Specifications.................................................................... 18
	Weight table...................................................................... 21
	List of lubricant and water....................................................... 23
	Outlines of service............................................................... 25
	General view of controls and gauges............................................... 28
	Torque list....................................................................... 30
10 Structure and function............................................................. 31
	Power train....................................................................... 33
	Power train system................................................................ 34
	Torque converter, transmission piping............................................. 36
	Transmission hydraulic system diagram............................................. 37
	Transmission hydraulic circuit diagram............................................ 38
	Torque converter.................................................................. 39
	Transmission...................................................................... 43
	Clutch............................................................................ 45
	Transmission control valve........................................................ 53
	Transmission solenoid valve....................................................... 56
	Pilot reducing valve.............................................................. 58
	Main relief valve................................................................. 59
	Torque converter outlet port valve................................................ 60
	Priority valve.................................................................... 61
	Transmission oil pressure system diagram.......................................... 62
	H-L selector valve and range selector valve....................................... 65
	Emergency manual spool............................................................ 67
	Electronic control modulation valve............................................... 68
	Pilot oil filter.................................................................. 71
	Accumulator valve................................................................. 72
	Flow valve........................................................................ 74
	Check valve....................................................................... 75
	Drive shaft....................................................................... 77
	Axle.............................................................................. 78
	Differential...................................................................... 80
	Final drive....................................................................... 87
	Axle mount, center hinge pin...................................................... 88
	Steering piping................................................................... 89
	Steering column, orbit roll....................................................... 90
	Hydraulic circuit diagram for steering............................................ 91
	Orbit-roll valve.................................................................. 92
	Steering demand valve............................................................. 93
	Overload relief valve............................................................. 94
	Steering relief valve............................................................. 96
	Operation of demand valve......................................................... 97
	Emergency steering................................................................107
	Brake piping......................................................................117
	Brake circuit diagram.............................................................118
	Brake valve.......................................................................119
	Charge valve......................................................................124
	Accumulator for system brake......................................................128
	Slack adjuster....................................................................129
	Brake circuit diagram.............................................................132
	Brake valve (dual circuit)........................................................133
	Brake valve (single circuit)......................................................135
	Brake pressure regulating valve...................................................140
	Accumulator (for brake)...........................................................141
	Accumulator for PPC valve.........................................................142
	Brake accumulator unit............................................................143
	Brake.............................................................................145
	Parking brake control.............................................................147
	Parking brake.....................................................................148
	Parking brake valve...............................................................149
	Hydraulic piping..................................................................151
	Work equipment hydraulic circuit diagram..........................................152
	Work equipment lever linkage......................................................158
	Hydraulic tank....................................................................159
	PPC valve.........................................................................161
	PPC relief valve..................................................................169
	Accumulator for PPC valve.........................................................170
	Main control valve (up to H30296).................................................171
	Relief valve (up to H30296........................................................173
	Safety valve (with suction).......................................................174
	Suction valve.....................................................................175
	Main control valve (H30297 and up)................................................176
	Safety valve with suction (H30297 and up).........................................178
	Anticavitation valve (H30297 and up)..............................................179
	Safety valve (H30297 and up)......................................................179
	Hydraulic safety system...........................................................186
	Hydraulic safety system location (up to H30431)...................................187
	Hydraulic safety valve (up to H30431).............................................188
	Work equipment linkage............................................................189
	Bucket............................................................................191
	Bucket positioner and boom kick-out...............................................192
	Machine monitor system............................................................199
	Main monitor......................................................................200
	Maintenance monitor...............................................................204
	Transmission auto-shift control system............................................206
	Transmission controller...........................................................211
	E.C.S.S...........................................................................213
	Sensors...........................................................................223
	Engine start circuit..............................................................229
	Ether start.......................................................................230
	Electric transmission control.....................................................235
	Combination switch................................................................236
	Kick-down, hold switch............................................................238
	Transmission electric circuit diagram.............................................239
	Transmission cut-off switch.......................................................244
	Transmission cut-off function.....................................................245
	Electric parking brake control....................................................246
	Air-conditioner...................................................................247
	Wiring diagrams...................................................................301
20 Testing and adjusting..............................................................329
	Standard value table for engine...................................................330
	Standard value table for chassis..................................................332
	Test certificate..................................................................335
	Standard value table for electrical parts.........................................339
	Tools for testing, adjusting and troubleshooting..................................351
	Adjusting valve clearance.........................................................353
	Measuring compression pressure....................................................357
	Measuring blow-by pressure........................................................359
	Testing and adjusting fuel injection timing.......................................361
	Mesuring exhaust color............................................................363
	Measuring intake air pressure (boost pressure)....................................364
	Measuring engine oil pressure.....................................................365
	Testing the fan belt tension......................................................366
	Measuring accelerator pedal.......................................................367
	Basic adjustment of accelerator pedal.............................................369
	Measuring operating force, travel of speed lever..................................371
	Measuring stall speed.............................................................372
	Measuring torque converter, transmission, parking brake oil pressure..............374
	Method of operating emergency manual spool........................................376
	Measuring clearance between tyre and wheel........................................378
	Measuring operating force of steering wheel.......................................379
	Measuring steering oil pressure...................................................381
	Measuring operating force, travel of brake pedal..................................383
	Measuring brake performance.......................................................384
	Testing brake oil pressure........................................................385
	Measuring brake disc wear.........................................................386
	Bleeding air from brake system....................................................387
	Measuring parking brake performance...............................................388
	Method of manual release of parking brake.........................................389
	Testing wear of parking brake disc................................................390
	Measuring work equipment control lever............................................391
	Measuring PPC valve pressure......................................................393
	Measuring work equipment..........................................................399
	Testing and adjusting bucket positioner...........................................401
	Testing and adjusting boom kick-out...............................................402
	Adjusting main monitor (speedometer modul)........................................404
	Checking for abnormality in fuel level sensor.....................................405
	Troubleshooting...................................................................409
	Points to remember when troubleshooting
..........................................410
	Sequence of events in troubleshooting.............................................411
	Precautions when carrying out maintenance.........................................412
	Handling connectors...............................................................419
	Checks before troubleshooting
....................................................420
	Method of using troubleshooting charts............................................421
	Connector types and mounting locations, connector pin arrangement diagram.........431
	Connection table for connector pin numbers........................................438
	Troubleshooting of engine system (S mode).........................................445
	Troubleshooting of main monitor system (M mode)...................................465
	Troubleshooting of maintenance monitor system (K mode)............................503
	Troubleshooting of electrical system (E mode).....................................523
	Troubleshooting of transmission controller system (A mode)........................561
	Troubleshooting of hydraulic and mechanical system (Chassis related) (T mode).....581
	Troubleshooting of ECSS (Electronically Controlled Suspension System) (D mode)....605
30 Disassembly and assembly...........................................................619
	Method of using manual............................................................621
	Precautions when carrying out operation...........................................622
	Special tool list.................................................................624
	Starting motor....................................................................626
	Alternator........................................................................627
	Engine oil cooler.................................................................628
	Fuel injection pump...............................................................631
	Water pump........................................................................637
	Turbocharger......................................................................638
	Thermostat........................................................................642
	Cylinder head.....................................................................646
	Torque converter charging pump....................................................664
	Torque converter, transmission....................................................665
	Torque converter..................................................................674
	Tranmission.......................................................................679
	Transmission clutch pack..........................................................690
	Parking brake.....................................................................711
	Transmission control valve........................................................716
	Transmission accumulator valve....................................................734
	Drive shaft.......................................................................737
	Front axle........................................................................741
	Rear axle.........................................................................744
	Front differential................................................................749
	Rear differential.................................................................754
	Differential......................................................................759
	Final drive.......................................................................770
	Center hinge pin..................................................................777
	Steering, orbit roll..............................................................791
	Steering valve....................................................................793
	Steering, switch pump.............................................................808
	Steering cylinder.................................................................812
	Brake valve.......................................................................814
	Right brake valve (tandem)........................................................816
	Left brake valve (single).........................................................818
	Slack adjuster....................................................................820
	Brake.............................................................................824
	Parking brake disc................................................................838
	Hydraulic tank....................................................................841
	Work equipment, PPC pump..........................................................844
	PPC valve.........................................................................851
	Main control valve................................................................853
	Bucket cylinder...................................................................861
	Boom cylinder.....................................................................863
	Hydraulic cylinder................................................................865
	Work equipment....................................................................871
	Counterweight.....................................................................876
	Fuel tank.........................................................................877
	Cab...............................................................................879
	Main monitor......................................................................881
	Maintenance monitor...............................................................883
	Air conditioner unit..............................................................884
	Air conditioner condenser.........................................................890
	Dry receiver......................................................................892
	Air conditioner compressor........................................................893
40 Maintenance standard...............................................................895
	Engine mount, transmission mount..................................................896
	Torque converter..................................................................897
	Transmission......................................................................898
	Transmission control valve........................................................908
	Drive shaft.......................................................................912
	Diffential........................................................................914
	Final drive.......................................................................916
	Axle mount........................................................................917
	Steerig column, orbit roll........................................................918
	Steering valve....................................................................920
	Steering cylinder mount...........................................................921
	Slack adjuster....................................................................922
	Brake valve.......................................................................923
	Brake.............................................................................926
	Parking brake.....................................................................928
	Torque converter, transmission pump...............................................929
	Steering, switch pump.............................................................930
	Hydraulic, PPC pump...............................................................931
	PPC valve.........................................................................932
	Cut-off valve.....................................................................933
	Main control valve................................................................934
	Boom cylinder.....................................................................938
	Bucket cylinder...................................................................939
	Center hinge pin..................................................................940
	Work equipment linkage............................................................942
	Bucket............................................................................944
	Bucket positioner and boom kick-out...............................................945

PLEASE NOTE:

⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]