Komatsu Wheel Loader WA420LC-Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA420LC-Series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA420LC-Series workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 949 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBMW24020 - Komatsu Wheel Loader WA420-1LC Shop Manual.pdf
SEAMU424KD10 - Komatsu Wheel Loader WA420-1LC Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEBMW24020 - Wheel Loader WA420-1LC Shop Manual.....2
CONTENTS.....5
10 ENGINE.....19
12 TESTING AND ADJUSTING.....19
STANDARD VALUE TABLE .....20
TOOL LIST FOR TESTING AND ADJUSTING .....23
VALVE CLEARANCE .....25
FUEL INJECTION TIMING.....26
ENGINE OIL PRESSURE AND TEMPERATURE.....27
BLOW-BY PRESSURE .....29
EXHAUST GAS COLOR .....30
ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE .....31
13 DISASSEMBLY AND ASSEMBLY .....33
STARTING MOTOR .....35
REMOVAL.....35
INSTALLATION.....35
ALTERNATOR .....36
REMOVAL.....36
INSTALLATION.....36
FUEL INJECTION PUMP.....37
REMOVAL.....37
INSTALLATION.....37
WATER PUMP.....38
REMOVAL.....38
INSTALLATION.....38
INJECTORS .....39
REMOVAL.....39
INSTALLATION.....40
CYLINDER HEAD.....41
REMOVAL.....41
INSTALLATION.....42
TURBOCHARGER .....43
REMOVAL.....43
INSTALLATION.....44
COMPRESSOR .....45
REMOVAL.....45
INSTALLATION.....45
AFTERCOOLER .....46
REMOVAL.....46
INSTALLATION.....47
RADIATOR .....48
REMOVAL.....48
INSTALLATION.....51
OIL COOLER .....53
REMOVAL .....53
INSTALLATION.....53
ENGINE .....54
REMOVAL.....54
INSTALLATlON .....60
FUEL TANK .....66
REMOVAL .....66
INSTALLATION.....66
20 POWER TRAIN.....67
21 STRUCTURE AND FUNCTION.....67
GENERAL.....68
HYDRAULIC CIRCUIT FOR POWER TRAIN.....70
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.....71
TORQUE CONVERTER AND TRANSMISSION PIPING .....72
TORQUE CONVERTER.....73
TORQUE CONVERTER OIL FILTER .....76
TORQUE CONVERTER OIL COOLER.....77
TORQUE CONVERTER RELIEF VALVE.....78
TRANSMISSION .....79
TRANSMISSION CONTROL VALVE .....87
UPPER VALVE.....88
LOWER VALVE.....89
SOLENOID VALVE.....91
EMERGENCY MANUAL SPOOL.....92
PRIORITY VALVE.....95
MODULATlNG VALVE AND QUICK RETURN VALVE.....96
ACCUMULATOR VALVE.....99
PILOT REDUCING VALVE.....102
TRANSMISSION PILOT FILTER.....103
TRANSFER .....104
DRIVE SHAFT.....105
AXLE MOUNT.....106
AXLE AND DIFFERENTIAL.....108
TORQUE PROPORTIONING DIFFERENTIAL.....113
FINAL DRIVE.....115
TIRE AND WHEEL.....116
22 TESTING AND ADJUSTING.....117
STANDARD VALUE TABLE.....118
TOOL LIST.....119
ENGINE SPEED.....120
OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION.....122
SHIFT LEVER .....124
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL.....125
TIRE AND WHEEL.....127
TROUBLESHOOTING.....129
PRECAUTIONS WHEN TROUBLESHOOTING.....130
METHOD OF READING TROUBLESHOOTING TABLES.....132
PREVENTING RECURRENCE OF TROUBLE.....134
JUDGEMENT ON POWER TRAIN.....135
TROUBLESHOOTING TABLE.....138
Machine does not move.....138
Excessive time lag when starting machine or shifting gear.....140
Torque converter oil temperature too high.....141
23 DISASSEMBLY AND ASSEMBLY.....143
TORQUE CONVERTER CHARGING PUMP.....145
REMOVAL .....145
INSTALLATION.....146
TORQUE CONVERTER, TRANSMISSION, TRANSFER .....147
REMOVAL.....147
INSTALLATION.....154
TORQUE CONVERTER .....161
DISASSEMBLY.....161
ASSEMBLY.....165
TRANSMISSION.....171
DISASSEMBLY.....171
DISASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER ASSEMBLY.....179
DISASSEMBLY OF NO. 3, 4 CARRIER ASSEMBLY.....181
DISASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING ASSEMBLY.....182
DISASSEMBLY OF NO. 4, 5 HOUSING ASSEMBLY.....183
ASSEMBLY.....184
ASSEMBLY OF NO. 4, 5 HOUSING ASSEMBLY.....184
ASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING ASSEMBLY.....185
ASSEMBLY OF NO. 3, 4 CARRIER ASSEMBLY.....186
ASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER ASSEMBLY.....187
ASSEMBLY OF TRANSMISSION.....189
TRANSFER ASSEMBLY .....197
DISASSEMBLY.....197
ASSEMBLY.....199
TRANSMISSION CONTROL VALVE.....205
REMOVAL.....205
INSTALLATION.....206
LOWER VALVE.....207
DISASSEMBLY.....207
ASSEMBLY.....207
UPPER VALVE.....209
DISASSEMBLY.....209
ASSEMBLY.....209
FRONT DIFFERENTIAL.....211
REMOVAL.....211
INSTALLATION.....214
REAR DIFFERENTIAL.....217
REMOVAL.....217
INSTALLATION.....218
DIFFERENTIAL.....219
DISASSEMBLY.....219
ASSEMBLY.....222
FRONT AXLE.....230
REMOVAL .....230
INSTALLATION.....233
REAR AXLE.....235
REMOVAL .....235
INSTALLATION.....239
DRIVE SHAFT.....243
DISASSEMBLY.....243
ASSEMBLY.....245
FINAL DRIVE.....247
DISASSEMBLY.....247
ASSEMBLY.....250
24 MAINTENANCE STANDARD.....255
TRANSMISSION AND ENGINE MOUNT.....256
TORQUE CONVERTER CHARGING PUMP .....258
TORQUE CONVERTER .....260
TORQFLOW TRANSMISSION .....262
1. TRANSMISSION.....262
2. TRANSMISSION CONTROL VALVE.....266
UPPER VALVE.....266
LOWER VALVE.....268
3. SOLENOID VALVE.....270
TRANSFER .....272
DIFFERENTIAL.....274
FINAL DRIVE .....276
DRIVE SHAFT .....277
AXLE MOUNT .....278
40 STEERING SYSTEM.....281
41 STRUCTURE AND FUNCTION.....281
HYDRAULIC PIPING .....282
HYDRAULIC CIRCUIT DIAGRAMS.....283
NORMAL STEERING.....283
GROUND DRIVEN STEERING.....283
STEERING CONTROL SYSTEM .....284
STEERING VALVE.....284
ORBIT-ROLL VALVE.....285
RELIEF VALVE.....286
STOP VALVE.....287
STEERING CYLINDER.....288
STEERING COLUMN AND ORBIT-ROLL .....289
CENTER HINGE PIN .....290
GROUND DRIVEN STEERING PUMP (OPTIONAL) .....291
DIVERTER VALVE (OPTIONAL) .....292
42 TESTING AND ADJUSTING.....293
STANDARD VALUE TABLE .....294
TOOL LIST .....294
STEERING WHEEL PLAY .....295
OPERATING FORCE OF STEERING WHEEL .....296
OPERATING TIME OF STEERING WHEEL .....297
STEERING CONTROL.....298
STEERING OIL PRESSURE.....299
GROUND DRIVEN STEERING PUMP.....301
TROUBLESHOOTING.....303
TROUBLESHOOTING TABLES.....304
1. Steering wheel does not turn.....304
2. Steering wheel is heavy.....305
3. Steering wheel wobbles or there is excessive shock.....306
4. Machine steers to one side when traveling.....306
5. Turning radius to left and right is different.....306
43 DISASSEMBLY AND ASSEMBLY.....307
STEERING VALVE.....308
DISASSEMBLY.....308
ASSEMBLY.....311
STEERING DEMAND VALVE.....316
DISASSEMBLY.....316
ASSEMBLY.....320
CENTER HINGE PIN.....324
REMOVAL.....324
INSTALLATION.....333
STEERING CYLINDER.....342
REMOVAL.....342
INSTALLATION.....343
DISASSEMBLY.....344
ASSEMBLY.....346
44 MAINTENANCE STANDARD.....349
STEERING COLUMN AND ORBIT-ROLL.....350
STEERING VALVE.....351
STEERING CYLINDER MOUNT.....352
STEERING CYLINDER.....354
CENTER HINGE PIN.....356
DIVERTER VALVE.....358
GROUND DRIVEN STEERING PUMP.....360
50 BRAKE AND AIR SYSTEM.....361
51 STRUCTURE AND FUNCTION.....361
AIR PIPING.....362
AIR CIRCUIT DIAGRAM.....362
AIR TANK.....363
WET TANK.....363
DRY TANK.....364
AIR DRYER.....365
SAFETY VALVE.....368
BRAKE VALVE.....369
BRAKE ACTUATED.....370
OPERATING IN BALANCE.....371
BRAKE RELEASED.....372
AIR GOVERNOR.....373
TWO-WAY VALVE.....375
BRAKE CHAMBER.....376
SLACK ADJUSTER.....378
BRAKE.....381
PARKING BRAKE.....383
PARKING BRAKE SOLENOID VALVE.....385
SPRING CYLINDER.....386
BRAKE CALIPER.....387
52 TESTING AND ADJUSTING.....389
STANDARD VALUE TABLE .....391
TOOL LIST.....392
BRAKE PEDAL.....393
AIR.....394
1. Measuring set pressure of air governor.....394
2. Measuring cut-off pressure of air pressure alarm buzzer.....395
3. Measuring safety valve.....396
AIR DRYER.....397
BRAKE PERFORMANCE.....399
BRAKE OIL PRESSURE.....400
WEAR OF BRAKE DISC.....401
AIR BLEEDING FROM BRAKE LINE.....402
PARKING BRAKE .....403
PERFORMANCE.....403
CHECKING AND ADJUSTING.....404
TROUBLESHOOTING.....407
TROUBLESHOOTING TABLES.....408
1. Air pressure does not rise at all.....408
2. Air pressure does not rise to the specified range.....409
3. Brake is ineffective or not very effective.....410
4. Brake does not release, or drags.....411
5. Parking brake does not release, or drags. (Applies to machines equipped with air parking brake.).....412
6. Air dryer troubleshooting.....413
53 DISASSEMBLY AND ASSEMBLY.....415
AIR GOVERNOR .....417
DISASSEMBLY .....417
ASSEMBLY.....418
AIR DRYER .....419
REMOVAL.....419
INSTALLATION.....419
DISASSEMBLY.....421
ASSEMBLY.....423
BRAKE VALVE .....425
REMOVAL.....425
INSTALLATION.....426
DISASSEMBLY.....427
ASSEMBLY.....429
BRAKE CHAMBER .....431
REMOVAL.....431
INSTALLATION.....433
DISASSEMBLY.....434
ASSEMBLY.....437
SLACK ADJUSTER .....441
REMOVAL.....441
INSTALLATION.....441
DISASSEMBLY.....442
ASSEMBLY.....443
BRAKE .....444
DISASSEMBLY.....444
ASSEMBLY.....450
SPRING CYLINDER.....458
REMOVAL.....458
INSTALLATION.....459
DISASSEMBLY.....460
ASSEMBLY.....462
PARKING BRAKE .....464
REMOVAL.....464
INSTALLATION.....466
PARKING BRAKE PAD.....468
REMOVAL .....468
INSTALLATION.....469
54 MAINTENANCE STANDARD.....471
BRAKE VALVE .....472
BRAKE CHAMBER .....474
SLACK ADJUSTER .....475
BRAKE.....476
PARKING BRAKE.....478
SPRING CYLINDER.....480
60 WORK EQUIPMENT SYSTEM.....483
61 STRUCTURE AND FUNCTION.....483
HYDRAULIC PIPING.....484
HYDRAULIC CIRCUIT DIAGRAM.....485
FOR 2-SPOOL.....485
FOR 3-SPOOL.....486
FOR 3-SPOOL, WITH GROUND DRIVEN STEERING AND SECURITY VALVE.....487
BUCKET LINKAGE.....488
BUCKET POSITIONER AND BOOM KICK-OUT.....490
HYDRAULIC TANK.....492
OIL FILTER BYPASS VALVE.....493
BREATHER.....494
HYDRAULIC PUMP.....495
MAIN CONTROL VALVE.....496
FOR 2-SPOOL.....496
FOR 3-SPOOL.....498
RELIEF VALVE.....506
SAFETY VALVE (WITH SUCTION VALVE).....507
SUCTION VALVE.....508
HYDRAULIC CYLINDER.....509
LIFT CYLINDER.....509
DUMP CYLINDER.....510
62 TESTING AND ADJUSTING.....511
STANDARD VALUE TABLE .....513
TOOL LIST .....514
DUMP AND LIFT CONTROL LEVERS .....515
HYDRAULIC PRESSURE .....517
LIFT ARM AND BUCKET .....519
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET .....520
BUCKET POSITIONER .....521
BOOM KICK-OUT .....522
TROUBLESHOOTING.....523
TROUBLESHOOTING TABLES.....524
1. Lift arm does not rise.....524
2. Lift arm moves slowly or does not have sufficient lifting power.....525
3. Lift arm movement becomes slow after it reaches a certain height.....526
4. Bucket cannot be held down with lift arm cylinder.....526
5. Lift arm has large hydraulic drift.....526
6. Lift arm movement is unsteady during work.....526
7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise".....526
8. Bucket does not tilt back.....527
9. Bucket moves slowly or has insufficient tilt back power.....528
10. Bucket movement becomes slow during tilt back.....529
11. Bucket cannot be held down by the bucket cylinder.....529
12. Bucket has large hydraulic drift.....529
13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold").....529
14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back".....529
15. Control levers of lift arm and dump move stiffly and sluggishly.....530
63 DISASSEMBLY AND ASSEMBLY.....531
HYDRAULIC TANK .....533
REMOVAL.....533
INSTALLATION.....536
HYDRAULIC FILTER .....539
REMOVAL.....539
INSTALLATION.....539
STEERING PUMP.....540
REMOVAL.....540
INSTALLATION.....541
MAIN CONTROL VALVE .....542
REMOVAL.....542
INSTALLATION.....544
DISASSEMBLY.....546
ASSEMBLY.....548
DUMP CYLINDER .....550
REMOVAL.....550
INSTALLATION.....552
LIFT CYLINDER.....553
REMOVAL.....553
INSTALLATION.....554
HYDRAULIC CYLINDER.....555
DISASSEMBLY.....555
ASSEMBLY.....557
WORK EQUIPMENT.....560
REMOVAL.....560
lNSTALLATlON.....563
COUNTERWEIGHT.....566
REMOVAL.....566
INSTALLATION.....566
64 MAINTENANCE STANDARD.....567
MAIN CONTROL VALVE.....568
(2 - Spool valve).....568
(3 - Spool valve).....570
DUMP CYLINDER.....572
LIFT CYLINDER.....573
BUCKET LINKAGE.....574
BUCKET POSITIONER AND BOOM KICK-OUT.....577
BUCKET.....578
HYDRAULIC PUMP.....579
80 ELECTRIC AND ELECTRONIC SYSTEM.....581
81 STRUCTURE AND FUNCTION.....581
ELECTRICAL WIRING DIAGRAM.....582
ELECTRICAL WIRING 3D CIRCUIT DIAGRAM.....582
ELECTRICAL WIRING CONNECTORS (CN) DIAGRAM.....582
ENGINE STARTING CIRCUIT .....583
ENGINE STOP CIRCUIT.....585
ELECTRICAL TRANSMISSION CONTROL .....586
COMBINATION SWITCH.....587
TRANSMISSION CUT-OFF SWITCH.....588
TRANSMISSION CUT-OFF SELECTOR SWITCH.....589
NEUTRALIZER RELAY.....590
KICK-DOWN SWITCH .....591
KICK-DOWN ELECTRIC CIRCUIT .....592
ELECTRICAL PARKING BRAKE CONTROL .....598
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) .....607
INDICATION ON MONITOR PANEL.....609
SENSORS.....611
ENGINE OIL LEVEL SENSOR.....612
COOLANT LEVEL SENSOR.....612
COOLANT TEMPERATURE SENSOR.....613
TORQUE CONVERTER OIL TEMPERATURE SENSOR.....613
PARKING BRAKE SENSOR.....614
ENGINE OIL PRESSURE SENSOR.....614
BRAKE CHAMBER STROKE SENSOR.....615
AIR PRESSURE SENSOR.....615
ROTATIONAL SPEED SENSOR.....616
FUEL GAUGE SENSOR.....617
WIRING HARNESS.....618
BUCKET POSITIONER AND BOOM KICK-OUT .....619
82 TESTING AND ADJUSTING.....625
STANDARD VALUE TABLE .....628
ADJUSTING SPEEDOMETER MODULE IN THE VEHICLE MONITOR .....631
TROUBLESHOOTING.....633
CHECKS BEFORE TROUBLESHOOTING.....634
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.....635
CONNECTOR TERMINAL NUMBERS.....637
PRECAUTION WHEN HANDLING CONNECTOR.....644
ELECTRICAL WIRING (3D) DIAGRAM.....646
ELECTRICAL CONNECTOR (CN) WIRING DIAGRAM.....646
ELECTRICAL CIRCUIT SYSTEM.....647
ENGINE STARTING AND STOP CIRCUIT SYSTEM.....647
TRANSMISSION CONTROL, PARKING BRAKE CIRCUIT SYSTEM.....648
ETHER INJECTION CIRCUIT SYSTEM.....649
KICK-DOWN CIRCUIT SYSTEM.....650
TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM.....651
POSITION OF CONNECTORS FOR TOUBLESHOOTING.....652
E-1 ENGINE DOES NOT START.....656
E-2 ENGINE DOES NOT STOP.....658
E-3 ENGINE STOPS WHEN TRAVELING.....658
E-4 PARKING BRAKE DOES NOT WORK. .....659
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING.....660
E-6 PARKING BRAKE IS RELEASED WHEN STARTING .....662
E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL. (PARKING BRAKE IS WORKING NORMALLY.) .....662
E-8 TRANSMISSION DOES NOT WORK NORMALLY. .....663
E-9 KICK-DOWN SWITCH DOES NOT WORK. (NORMAL Fl - F4 SWITCHES CORRECTLY) .....684
E-10 KICK-DOWN ONLY IS ON. SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION.) .....687
E-11 KICK-DOWN OPERATION IS NOT CANCELED. .....688
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.....690
E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.....690
TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM.....693
POSITION OF CONNECTORS TROUBLESHOOTING .....694
M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS.....699
a) None of monitor panel lights up. .....699
b) Except for speedometer module, none of monitor panel lights up. .....699
c) None of CAUTION items light up. .....699
d) Some other parts do not light up.....699
M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT. .....700
M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT). .....701
a) (Engine oil level) flashes. .....701
b) (Radiator water level) flashes.....702
M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY. (SWITCH POSITIONS ARE NORMAL).....704
a) (Transmission cut-off) lights up. .....704
b) (Parking brake) lights up. .....705
c) (Working lamp) lights up. .....705
M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES. .....707
a) Engine oil pressure system. .....707
b) Alternator system. .....707
M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CAUTION ITEM FLASHES. .....708
a) Engine oil pressure system. .....708
b) Alternator system. .....708
M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES.....710
a) (Charge level) flashes. .....710
b) (Fuel level) flashes. .....710
c) (Brake line failure) flashes. .....710
d) (Engine oil pressure) flashes. .....710
e) (Radiator water level) flashes. .....710
f) (Air pressure) flashes. .....711
g) (Engine water temperature) flashes. .....711
h) (Torque converter oil temperature) flashes. .....711
M-8 SPEED SENSOR DISPLAY STAYS AT “0”.....714
M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY.....715
a) If high beam does not light up. .....715
b) If high beam lights up when head lamp switch is OFF. (Dimmer switch at Lo position) .....715
c) If high beam display lights up when head lamp dimmer switch is at Lo beam position. .....716
M-10 TURN SIGNAL LAMP DOES NOT FLASH. TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING. .....717
a) If turn signal lamp does not flash. .....717
b) If turn signal lamp stays ON or does not stop flashing. .....717
M-11 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES FOR 1 SEC. CAUTION ITEM IS FLASHING.....718
M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.....719
M-13 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS F.....720
M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP.....720
M-15 WHEN STARTING SWITCH IS TURNED TO ON POSITION, LAMPS DO NOT LIGHT UP FOR 4 SEC. WHEN LAMP SWITCH IS ON, LAMPS DO NOT LIGHT UP. .....721
a) None of panel lights up. .....721
b) Some of panel lamps do not light up. .....721
M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING STAYS ON.....722
M-17 SERVICE METER DOES NOT WORK. .....723
M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED. .....723
M-19 AIR PRESSURE GAUGE. .....724
a) If nothing is displayed in display area. .....724
b) If indicator remains at maximum level. .....724
M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE. .....725
a) If nothing is displayed in display area. .....725
b) If indicator remains at minimum level. .....725
M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE. .....726
a) If nothing is displayed in display area. .....726
b) If indicator remains at minimum level. .....726
M-22 ABNORMALITY IN FUEL GAUGE. .....727
a) If nothing is displayed in display area. .....727
b) If indicator remains at FULL. .....727
83 DISASSEMBLY AND ASSEMBLY.....729
MACHINE MONITOR .....730
REMOVAL.....730
INSTALLATION.....730
90 OTHER.....731
93 DISASSEMBLY AND ASSEMBLY.....731
CAB.....732
REMOVAL.....732
INSTALLATION.....732
97 GEAR PUMP.....733
GENERAL.....734
PRINCIPLE OF OPERATION.....735
PRESSURE LOADED TYPE GEAR PUMP.....738
FIXED SIDE PLATE TYPE GEAR PUMP.....740
SA SERIES.....741
STRUCTURE.....741
TESTING AND ADJUSTING.....745
DISASSEMBLY.....748
ASSEMBLY.....752
MAINTENANCE STANDARD.....757
99 METRIC CONVERSIONS.....759
SEAMU424KD10 - Wheel Loader WA420-1LC Operation & Maintenance Manual.....779
CONTENTS.....783
OPERATION .....791
GENERAL LOCATIONS AND SPECIFICATIONS .....792
GENERAL LOCATIONS .....792
PERFORMANCE .....792
ENGINE .....792
INSTRUMENTS AND CONTROLS .....793
MONITOR PANEL .....793
CHECK MONITOR GROUP.....793
Engine Oil Level Monitor .....795
Coolant Level Monitor .....796
CAUTION MONITOR GROUP .....796
Charge Monitor.....796
Fuel Level Monitor .....796
CAUTION MONITOR GROUP.....797
Brake Line Failure Monitor .....797
Engine Oil Pressure Monitor .....797
Coolant Level Monitor .....797
Air Pressure Monitor .....798
Coolant Temperature Monitor .....798
Torque Converter Oil Temperature Monitor .....798
METER GROUP PILOT DISPLAY .....799
Parking Brake Pilot Lamp .....799
Pilot Lamp for Workhg Lamp .....800
Transmission Cut-off Selector Pilot Lamp .....800
Air Pressure Gauge .....800
Engine Cooling Water Temperature Gauge .....801
Torque Converter Oil Temperature Gauge.....801
Fuel Gauge .....801
Turn Signal Pilot Lamp .....801
High Beam Pilot Lamp .....802
Speedometer.....802
Service Meter.....802
SWITCHES .....803
TRANSMISSION CUT-OFF SELECTOR SWITCH .....803
ETHER START SWITCH .....804
HORN BUTTON .....804
HAZARD LAMP SWITCH .....804
PARKING BRAKE SWITCH.....805
WORKING LAMP SWITCH .....806
STARTING SWITCH.....806
LAMP SWITCHES .....806
Lamp switch.....806
Turn signal lever .....807
Dimmer switch.....807
ROOM LAMP SWITCH .....807
CIGARETTE LIGHTER .....808
KICKDOWN SWITCH .....808
FRONT WIPER SWITCH.....809
REAR WlPER SWITCH.....809
LEVERS AND PEDALS .....810
DIRECTIONAL LEVER .....810
SPEED CONTROL LEVER .....811
SPEED CONTROL LEVER STOPPER .....811
STEERING COLUMN TILT LEVER .....811
ACCELERATOR PEDAL .....811
BRAKE PEDALS .....812
Right brake pedal .....812
Left brake pedal .....812
LIFT ARM CONTROL LEVER .....813
BUCKET CONTROL LEVER .....814
SAFETY LOCK .....814
AIR CLEANER SERVICE INDICATOR .....814
SAFETY BAR.....815
WORK EQUIPMENT CONTROL LEVER .....815
CIRCUIT BREAKER (MAIN) .....816
DOOR-OPEN LOCK .....816
HOOD TILT LOCK .....817
FUSE BOX .....817
OPERATOR’S SEAT .....819
FORWARD-BACKWARD ADJUSTMENT .....819
SEAT ANGLE ADJUSTMENT .....819
SEAT CUSHION ADJUSTMENT .....819
BACKREST ADJUSTMENT.....819
SEAT HEIGHT ADJUSTMENT .....819
RIGHT SIDE ARMREST .....819
FORWARD-BACKWARD ADJUSTMENT .....819
ANGLE ADJUSTMENT .....819
SEAT BELT .....820
CHECK BEFORE STARTING .....821
WALK-AROUND CHECK .....821
CHECK MONITOR PANEL .....821
CHECK AND REFILL COOLANT .....822
CHECK OIL LEVEL AND REFIL IN THE ENGINE OIL PAN.....822
CHECK FUEL LEVEL AND REFILL FUEL .....823
CHECK AIR CLEANER SERVICE INDICATOR .....823
DRAIN WATER FROM AIR TANK.....824
CHECK FOR SEDIMENT AND WATER IN THE WATER SEDIMENTOR .....824
FUEL-WATER SEPARATOR - DRAINING WATER AND SEDIMENT .....825
DRIVE BELT - INSPECTION .....825
FAN - INSPECTlON .....825
OPERATlNG YOUR MACHINE .....827
BEFORE STARTING THE ENGINE .....827
TO START THE ENGINE.....828
SPECIAL STARTING.....828
CHECKS AFTER STARTING.....829
TO MOVE THE MACHINE OFF.....829
CHANGING GEAR SPEED.....830
CHANGING DIRECTION.....831
TURNING.....831
TO STOP THE MACHINE.....832
TO STOP THE ENGINE.....833
MAXIMUM DEPTH OF WATER.....833
IF WHEEL BRAKE DOES NOT WORK.....833
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.....834
LOWER THE CENTER OF GRAVI-IY WHEN TURNING.....834
BRAKING ON DOWNHU SL;OPES.....834
IF ENGINE STOPS.....834
PROPER BUCKET AND TIRE.....835
ADJUSTMENT OF WORK EQUIPMENT.....836
ADJUSTING BOOM KICKOUT.....836
ADJUSTING BUCKET POSITIONER.....837
BUCKET LEVEL INDICATOR.....837
HANDLING THE TIRES.....838
PRECAUTIONS WHEN HANDLING ilRES.....838
PRECAUTIONS WHEN DRIVING MACHINE.....839
TIRE PRESSURE.....840
INFLATING TIRES.....840
TOWING.....842
TOWING THE MACHINE.....842
WHEN ENGINE CAN BE USED.....842
WHEN ENGINE CANNOT BE USED.....842
RELEASING PARKING BRAKE.....843
COLD WEATHER OPERATION.....844
PREPARATION FOR LOW TEMPERATURE.....844
FUEL AND LUBRICANTS.....844
COOLANT.....844
BATTERY.....844
STARTING IN COLD WEATHER.....845
CAUTIONS AFTER COMPLETION OF WORK.....846
AFTER COLD WEATHER.....846
MAINTENANCE.....847
PERIODIC MAINTENANCE.....848
BLEEDING AIR FROM CIRCUIT.....848
BLEEDING AIR FROM HYDRAULIC CIRCUIT.....848
BLEEDING AIR FROM FUEL SYSTEM.....849
LOW PRESSURE LINES AND FUEL FILTER(S) VENTING.....849
HIGH PRESSURE LINES-VENTING.....849
PERIODICAL PART REPLACEMENT .....850
MAINTENANCE TABLE.....851
OIL FILLER AND LEVEL GAUGE POSITIONS .....855
CHECK BEFORE STARTING .....856
EVERY 50 HOURS SERVICE .....856
FUEL TANK .....856
TIRE .....856
EVERY 100 HOURS SERVICE .....857
HYDRAULIC TANK .....857
LUBRICATING .....857
AIR CONDITIONER FILTER-IF EQUIPPED .....858
INITIAL 250 HOURS SERVICE .....858
TRANSMlSSlON OIL FILTER .....858
EVERY 250 HOURS SERVICE.....859
ENGINE OIL PAN AND FfLTER.....859
AIR INTAKE SYSTEM - INSPECTION .....860
AIR CONDlTlONER COMPRESSOR BELT-IF EQUIPPED .....860
WHEEL HUB NUTS .....861
LUBRICATING .....862
CHECK ELECTROLYTE LEVEL IN BATTERY .....864
EVERY 500 HOURS SERVICE .....865
FUEL FILTERS .....865
TRANSMISSION OIL FILTER .....866
LUBRICATING .....866
AIR DRYER .....866
ANTIFREEZE CONCENTRATION - CHECK .....867
COOLANT ADDITIVE CONCENTRATION .....867
COOLANT FILTER .....868
EVERY 1000 HOURS SERVICE.....869
TRANSMISSION CASE AND STRAINER .....869
TRANSMISSION CASE BREATHER .....870
LUBRICATING .....871
ENGINE VALVES .....872
DRIVE BELT TENSION - CHECK .....876
DRIVE BELT, TENSIONER BEARING AND FAN HUB - INSPECTION .....877
EVERY 2000 HOURS SERVICE .....879
HYDRAULIC TANK AND FILTER .....879
HYDRAULlC TANK BREATHER .....880
DRIVE AXLES .....881
AIR CONDITIONER FILTER - IF EQUIPPED .....882
BRAKE DISC .....882
INTERNAL PART OF AIR DRYER .....882
COOLANT CHANGE AND FLUSHING THE SYSTEM .....883
COOLANT.....883
DCA4 UNIT MAINTENANCE GUIDE.....883
VlBRATlON DAMPER - INSPECTION. .....887
AIR COMPRESSOR - INSPECTlON .....887
AIR COMPRESSOR DISCHARGE - INSPECTION.....888
AIR COMPRESSOR lNTAKE - INSPECTION .....889
WHEN REQUIRED .....891
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT .....891
CHECKING.....891
CLEANING OR REPLACING OUTER ELEMENT.....891
REPLACING INNER ELEMENT.....892
CLEANING OUTER ELEMENT .....892
CHECK AND REFILL TRANSMISSION OIL .....893
CLEAN RADlATOR TIRES.....894
CHECK AND REFILL DRIVE AXLE OIL .....894
CLEAN DRIVE AXLE HOUSING BREATHER .....895
CLEAN AIR CONDlTlONER CONDENSER-IF EQUIPPED .....895
CHECK AIR CONDlTlONER REFRIGERANT CHARGE-IF EQUIPPED .....896
LUBRICATING .....897
CHECK AND REFILL WINDOW WASHING FLUID .....897
WATER SEDIMENTOR .....898
REPLACING BUCKET TEETH .....898
IF THE BUCKET IS EQUIPPED WITH BOLT-ON TOOTH .....898
IF THE BUCKET IS EDUIPPED WITH BOLT-ON TOOTH .....899
IF THE BUCKET IS EQUIPPED WITH TIP TOOTH .....899
ADJUSTMENT.....900
ADJUSTING PARKING BRAKE .....900
ADJUSTING LENGTH OF LEVER .....901
TROUBLE SHOOTING GUIDE .....902
ELECTRICAL SYSTEM .....902
ENGINE .....903
CHASSIS.....904
TRANSMISSION.....904
AXLE.....904
DISC BBAKE.....904
PARKlNG BRAKE.....905
STEERING.....905
HYDRAULIC SYSTEM.....905
SERVICE METER.....906
MACHINE AND ENGINE SERIAL NUMBERS.....906
FUEL, COOLANT AND LUBRICANTS.....907
MEMORANDA.....912
SAFETY AND OPERATION.....913
SAFETY HINTS.....914
OPERATION.....914
GENERAL.....914
CHECKING JOBSITE CONDITIONS.....916
BEFORE STARTING OPERATION.....917
CHECK BEFORE STARTING.....917
PRECAUTIONS WHEN GETTING ON THE MACHINE.....919
PRECAUTIONS WHEN STARTING THE ENGINE.....919
CHECKS AFTER STARTING THE ENGINE.....920
DURING OPERATION.....920
ATTENTlON TO SURROUNDINGS.....921
RESTRICTIONS CREATED BY JOBSITE.....923
PARKING.....925
PRECAUTIONS FOR MAINTENANCE.....926
GENERAL.....926
BEFORE MAINTENANCE.....928
DURING MAINTENANCE.....929
MISCELLANEOUS.....930
BUCKET OPERATION.....931
EXCAVATION.....931
PRECAUTIONS WHEN SCOOPING UP MATERIALS.....934
LEVELING.....934
LOAD AND CARRY OPERATIONS.....935
LOADING.....935
CROSS DRIVE LOADING.....935
V-SHAPE LOADING.....935
OPERATING THE CAB HEATER.....936
EQUIPMENT ON CONTROL PANEL.....936
FAN SPEED SWITCH.....936
TEMPERATURE CONTROL LEVER.....936
AIR INTAKE SELECTOR LEVER.....936
METHOD OF OPERATlON.....937
OPERATING THE AIR CONDITIONER-IF EQUIPPED.....938
EQUIPMENT ON CONTROL PANEL.....938
FAN SPEED SWITCH.....938
AIR CONDITIONER SWITCH.....938
AIR INTAKE SELECTOR LEVER.....938
TEMPERATURE CONTROL LEVER.....939
PRECAUTIONS FOR USING AIR CONDITIONER’.....940
HANDLING THE AIR CONDITIONER IN SEASON.....940
HANDLING THE AIR CONDITIONER IN OFF-SEASONS.....940
LOCKING CAP.....941
HANDLING OF BATTERY.....942
PRECAUTIONS FOR CHARGING BATTERY.....942
REMOVAL AND INSTALLATION OF BATTERY.....942
STARTING ENGINE WITH A BOOSTER CABLE.....943
TRANSPORTATION.....944
STORAGE.....945
BEFORE STORAGE.....945
DURING STORAGE.....946
AFTER STORAGE.....946
COOLANT AND LUBRICANTS.....947
MEMORANDA.....948
Komatsu Wheel Loader WA420LC-Series Repair Service Manual
