Komatsu WA420-3 Wheel Loader Shop Manual VEBM470104 PDF

Description

Komatsu WA420-3 Wheel Loader Shop Manual VEBM470104 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA420-3 Wheel Loader Shop Manual VEBM470104 – PDF DOWNLOAD 

Language : English
Pages : 970
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA420-3 Wheel Loader Shop Manual VEBM470104 – PDF DOWNLOAD 

Serial Number WA420H20051 and up

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

DESCRIPTION:

Komatsu WA420-3 Wheel Loader Shop Manual VEBM470104 – PDF DOWNLOAD 

Serial Number WA420H20051 and up

FOREWORD:
GENERAL:

• 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.

S.V 24/12/24