Komatsu WA420-3 15001 & Up SMEW4200M0 (Preview)
COVER
CONTENTS
SAFETY
FOREWORD
01 GENERAL
– GENERAL ASSEMBLY DRAWING
– SPECIFICATIONS
– WEIGHT TABLE
– LIST OF LUBRICANT AND WATER
10 STRUCTURE AND FUNCTION
– POWER TRAIN
– POWER TRAIN SYSTEM
– TORQUE CONVERTER,TRANSMISSION PIPING
– TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
– TORQUE CONVERTER
– TORQUE CONVERTER OIL FILTER
– TRANSMISSION
– TRANSMISSION CONTROL VALVE
– TRANSMISSION SOLENOID VALVE
– PILOT OIL FILTER
– DRIVE SHAFT
– AXLE
– DIFFERENTIAL
– FINAL DRIVE
– AXLE MOUNT,CENTER HINGE PIN
– STEERING PIPING
– STEERING COLUMN
– STEERING VALVE
– ORBIT-ROLL VALVE
– STOP VALVE
– BRAKE PIPING
– BRAKE CIRCUIT DIAGRAM
– BRAKE VALVE
– CHARGE VALVE
– ACCUMULATOR(FOR BRAKE)
– SLACK ADJUSTER
– BRAKE
– PARKING BRAKE CONTROL
– PARKING BRAKE
– PARKING BRAKE SOLENOID VALVE
– PARKING BRAKE VALVE
– HYDRAULIC PIPING
– WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
– WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
– WORK EQUIPMENT LEVER LINKAGE
– HYDRAULIC TANK
– STEERING RELIEF VALVE
– MAIN CONTROL VALVE
– WORK EQUIPMENT LINKAGE
– BUCKET
– BUCKET POSITIONER AND BOOM KICK-OUT
– CAB
– AIR CONDITIONER
– ELECTRIC CIRCUIT DIAGRAM
– SENSORS
– ENGINE STARTING CIRCUIT
– ENGINE STOP CIRCUIT
– ENGINE STOP SOENOID VALVE
– ELECTRIC TRANSMISSION CONTROL
– KICK-DOWN SWITCH
– KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
– TRANSMISSION CUT-OFF SWITCH
– TRANSMISSION CUT-OFF FUNCTION
20 TESTING AND ADJUSTING
– STANDARD VALVE TABLE FOR ENGINE
– STANDARD VALVE TABLE FOR CHASSIS
– STANDARD VALVE TABLE FOR ELECTRICAL PARTS
– TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING
– MEASURING ENGINE SPEED
– MEASURING EXHAUST COLOR
– MEASURING EXHAUST GAS TEMPERATURE
– ADJUSTING VALVE CLEARANCE
– TESTING AND ADJUSTING FAN BELT TESION
– MEASURING ACCELERATOR PEDAL
– MEASURING OPERATING FORCE,TRAVEL OF SPEED LEVER
– MEASURING TORQUE CONVERTER,TRANSMISSION PARKING BRAKE OIL PRESSURE
– METHOD OF OPERATING EMERGENCY MANUAL SPOOL
– MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
– TESTING AND ADJUSTING STEERING WHEEL
– TESTING AND ADJUSTING STEERING CONTROL
– MEASURING STEERING OIL PRESSURE
– MEASURING OPERATING FORCE,TRAVEL OF BRAKE PEDAL
– MEASURING BRAKE PERFORMANCE
– TESTING BRAKE OIL PRESSURE
– MEASURING BRAKE DISC WEAR
– BLEEDING AIR FROM BRAKE SYSTEM
– MEASURING PARKING BRAKE PERFORMACE
– METHOD FOR MANUAL RELEASE OF PARKING BRAKE
– TESTING WEAR OF PARKING BRAKE DISC
– ADJUSTING WORK EQUIPMENT LINGAGE
– MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
– MEASURING WORK EQUIPMENT
– TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH
– TESTING AND ADJUSTING BOOM PROXIMITY SWITCH
– CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
– ADJUSTING BOOM,BUCKET ANGLE POTENTIOMETER
– TROUBLESHOOTING
— POINTS TO REMEMBER WHEN TROUBLESHOOTING
— SEQUENCE OF EVENTS IN TROUBLESHOOTING
— PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
— CHECKS BEFORE TROUBLESHOOTING
— CONNECTOR TYPES AND MOUNTING LOCATIONS
— CONNECTOR PIN ARRANGEMENT DIAGRAM
— CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS
— TRBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)
— E-1 ENGINE DOES NOT START
— E-2 Transmission does not work normally
—- a) Problem in common circuit for transmission
—- b) Problem in H-L circuit
—- c) Problem in speed circuit
—- d) Problem in 4th circuit(does not enter 4th)
—- e) Contact in H-L circuit
—- f) Contact speed circuit
—- g) Contact in 4th circuit(always stays in 4th)
—- h) Problem in FORWARD circuit(REVERSE is normal)
—- i) Problem in REVERSE circuit(FORWARD is normal)
—- j) Problem in common circuit for FORWARD and REVERSE(does not travel forward or in reverse)
—- k) Contact in FORWARD circuit
—- l) Contact in REVERSE circuit
—- m) Problem in common circuit for FORWARD and REVERSE
— E-3 Kick-down switch does not work(the regular F1 to F4 shifts normally)
— E-4 Kick-down works only when kick-down switch is ON(Kick-down switch relay does not hold in position)
— E-5 Kick-down is not canceled
—- a)Not canceled when F/R lever is operated from F to N or R
—- b)Not canceled when speed lever is operated from 2 to other position
— E-6 Kick-down switch is actuated by mistake when traveling in 2nd
— TROUBLESHOOTING OF HYDRAULIC AND ME-CHANICAL SYSTEM
— POWER TRAIN
—- T-1 Machine does not start
—- T-2 Travel speed is slow,thrusting power is weak, lacks power on slopes
—- T-3 Excessive shock when starting machine or shifting gear
—- T-4 Excessive time lag when starting machine or shifting gear
—- T-5 Torque converter oil temperature is high
— STEERING SYSTEM
—- T-6 Steering dose not turn
—- T-7 Steering wheel is heavy
—- T-8 Steering wheel wobbles or there is excessive shock
—- T-9 Machine steers to one side when travling
—- T-10 Turning radius to left and right is different
— BRAKE SYSTEM
—- T-11 Brakes do not work or braking effect is poor
—- T-12 Brakes are not released or brakes drag
—- T-13 Parking brake is not released or brake drags
— WORK EQUIPMENT
—- T-14 Boom does not rise
—- T-15 Boom movement is slow or boom lacks lifting power
—- T-16 When boom is raised,it moves slowly at a certain height
—- T-17 Bucket cannot be pushed with boom cylinder(bucket floats)
—- T-18 Excessive hydraulic drift of boom
—- T-19 Boom shakes during operation
—- T-20 Boom drops momentarily when control level is operated from HOLD to RAISE
—- T-21 Bucket does not tilt back
—- T-22 Bucket movement is slow or tilt-back lacks power
—- T-23 Bucket movement becomes slow during tilt-back operation
—- T-24 Bucket cannot be pushed with bucket cylinder
—- T-25 Excessive hydraulic drift of bucket
—- T-26 Bucket shakes during loading operation(Main control valve at HOLD)
—- T-27 Bucket dumps momentarily when control level is operated from HOLD to TIILT
—- T-28 Boom,bucket contol levers are heavy or do not move smoothly
30 DISASSEMBLY AND ASSEMBLY
– METHOD OF USING MANUAL
– PRECAUTIONS WHEN CARRYING OUT OPERATION
– GENERAL TOOL LIST
– RADIATOR
— REMOVAL
— INSTALLATION
– ENGINE
— REMOVAL
— INSTALLATION
– TORQUE CONVERTER CHARGING PUMP
— REMOVAL
— INSTALLATION
– TORQUE CONVERTER,TRANSMISSION
— REMOVAL
— INSTALLATION
– TORQUE CONVERTER
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION CLUTCH PARK
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION CONTROL VALVE
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– TRANSMISSION ACCUMULATOR VALVE
— DISASSEMBLY
— ASSEMBLY
– DRIVE SHAFT
— DISASSEMBLY
— ASSEMBLY
– FRONT AXLE
— REMOVAL
— INSTALLATION
– REAR AXLE
— REMOVAL
— INSTALLATION
– FRONT DIFFERENTIAL
— REMOVAL
— INSTALLATION
– REAR DIFFERENTIAL
— REMOVAL
— INSTALLATION
– DIFFERENTIAL
— DISASSEMBLY
— ASSEMBLY
– FINAL DRIVE
— DISASSEMBLY
— ASSEMBLY
– CENTER HINGE PIN
— REMOVAL
— INSTALLATION
– STEERING VALVE
— REMOVAL
— INSTALLATION
– STEERING DEMAND VALVE
— DISASSEMBLY
— ASSEMBLY
– STEERING VALVE
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– STEERING CYLINDER
— REMOVAL
— INSTALLATION
– BRAKE VALVE
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
– PARKING BRAKE DISC
— REMOVAL
— INSTALLATION
– HYDRAULIC TANK
— REMOVAL
— INSTALLATION
– HYDRAULIC FILTER
— REMOVAL
— INSTALLATION
– HYDRAULIC,STEERING,SWITCH,PPC PUMP
— REMOVAL
— INSTALLATION
– MAIN CONTROL VALVE
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMNBLY
– BUCKET CYLINDER
— REMOVAL
— INSTALLATION
– BOOM CYLINDER
— REMOVAL
— INSTALLATION
– HYARAULIC CYLINDER
— DISASSEMBLY
— ASSEMBLY
– WORK EQUIPMENT
— REMOVAL
— INSTALLATION
– COUNTERWEIGHT
— REMOVAL
— INSTALLATION
– FUEL TANK
— REMOVAL
— INSTALLATION
– CAB,FLOOR FRAME
— REMOVAL
— INSTALLATION
– CAB
— REMOVAL
— INSTALLATION
– MAIN MONITOR
— REMOVAL
— INSTALLATION
– AIR CONDITIONER UNIT
— REMOVAL
— INSTALLATION
– AIR CONDITIONER CONDENSER
— REMOVAL
— INSTALLATION
– DRY RECEIVER
— REMOVAL
— INSTALLATION
– AIR CONDITIONER CONDENSER COMPRESSOR
— REMOVAL
— INSTALLATION
40 MAINTENANCE STANDARD
– ENGINE MOUNT,TRANSMISSION MOUNT
– TORQUE CONVERTER
– TRANSMISSION
– TRANSMISSION CONTROL VALVE
– DRIVE SHAFT
– DIFFERENTIAL
– FINAL DRIVE
– AXLE MOUNT
– STEERING COLUMN
– STEERING VALVE
– STEERING CYLINDER MOUNT
– SLACK ADJUSTER
– BRAKE VALVE
– BRAKE
– PARKING BRAKE
– TORQUE CONVERTER,TRANSMISSION PUMP
– STEERING,SWITCH PUMP
– HYSRAULIC,PPC PUMP
– CUT-OFF VALVE
– MAIN CONTROL VALVE
– HYDRAULIC CYLINDER
– CENTER HINGE PIN
– WORK EQUIPMENT LINKAGE
– BUCKET
– BUCKET POSITIONER AND BOOM KICK-OUT
90 ELECTRIC CIRCUIT DIAGRAM
– ELECTRIC CIRCULT DIAGRAM
– AIR CONDITIONER WIRING DIAGRAM(1/2)
– AIR CONDITIONER WIRING DIAGRAM(2/2)
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