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Komatsu WA420-1LC Wheel Loader Shop Manual A25001 and up – PDF DOWNLOAD
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Komatsu WA420-1LC Wheel Loader Shop Manual A25001 and up
MACHINE MODEL SERIAL NUMBERS
WA420-1 LC A25001 and up
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Description
Komatsu WA420-1LC Wheel Loader Shop Manual A25001 and up
FILE DETAILS:
Komatsu WA420-1LC Wheel Loader Shop Manual A25001 and up
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA420-1LC
Serial Number: A25001 and up
Book Code: CEBMW24020
Language: English
Pages: 777
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA420-1LC Wheel Loader Shop Manual A25001 and up
1 GENERAL :
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, FUNCTION AND MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts. It 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, ADJUSTING AND TROUBLESHOOTING:
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.
TABLE OF CONTENTS:
Komatsu WA420-1LC Wheel Loader Shop Manual A25001 and up
MAIN MENU................................................................................................................................................ 0 CONTENTS................................................................................................................................................. 4 10 ENGINE................................................................................................................................................ 18 12 TESTING AND ADJUSTING............................................................................................................................. 18 STANDARD VALUE TABLE ............................................................................................................................ 19 TOOL LIST FOR TESTING AND ADJUSTING ............................................................................................................. 22 VALVE CLEARANCE ................................................................................................................................. 24 FUEL INJECTION TIMING............................................................................................................................ 25 ENGINE OIL PRESSURE AND TEMPERATURE.............................................................................................................. 26 BLOW-BY PRESSURE ................................................................................................................................ 28 EXHAUST GAS COLOR ............................................................................................................................... 29 ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE ......................................................................................... 30 13 DISASSEMBLY AND ASSEMBLY ......................................................................................................................... 32 STARTING MOTOR .................................................................................................................................. 34 REMOVAL...................................................................................................................................... 34 INSTALLATION................................................................................................................................. 34 ALTERNATOR ...................................................................................................................................... 35 REMOVAL...................................................................................................................................... 35 INSTALLATION................................................................................................................................. 35 FUEL INJECTION PUMP.............................................................................................................................. 36 REMOVAL...................................................................................................................................... 36 INSTALLATION................................................................................................................................. 36 WATER PUMP....................................................................................................................................... 37 REMOVAL...................................................................................................................................... 37 INSTALLATION................................................................................................................................. 37 INJECTORS ....................................................................................................................................... 38 REMOVAL...................................................................................................................................... 38 INSTALLATION................................................................................................................................. 39 CYLINDER HEAD.................................................................................................................................... 40 REMOVAL...................................................................................................................................... 40 INSTALLATION................................................................................................................................. 41 TURBOCHARGER .................................................................................................................................... 42 REMOVAL...................................................................................................................................... 42 INSTALLATION................................................................................................................................. 43 COMPRESSOR ...................................................................................................................................... 44 REMOVAL...................................................................................................................................... 44 INSTALLATION................................................................................................................................. 44 AFTERCOOLER ..................................................................................................................................... 45 REMOVAL...................................................................................................................................... 45 INSTALLATION................................................................................................................................. 46 RADIATOR ........................................................................................................................................ 47 REMOVAL...................................................................................................................................... 47 INSTALLATION................................................................................................................................. 50 OIL COOLER ...................................................................................................................................... 52 REMOVAL ..................................................................................................................................... 52 INSTALLATION................................................................................................................................. 52 ENGINE .......................................................................................................................................... 53 REMOVAL...................................................................................................................................... 53 INSTALLATlON ................................................................................................................................ 59 FUEL TANK ....................................................................................................................................... 65 REMOVAL ..................................................................................................................................... 65 INSTALLATION................................................................................................................................. 65 20 POWER TRAIN........................................................................................................................................... 66 21 STRUCTURE AND FUNCTION............................................................................................................................ 66 GENERAL.......................................................................................................................................... 67 HYDRAULIC CIRCUIT FOR POWER TRAIN............................................................................................................ 69 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.................................................................................................... 70 TORQUE CONVERTER AND TRANSMISSION PIPING ....................................................................................................... 71 TORQUE CONVERTER................................................................................................................................. 72 TORQUE CONVERTER OIL FILTER ..................................................................................................................... 75 TORQUE CONVERTER OIL COOLER...................................................................................................................... 76 TORQUE CONVERTER RELIEF VALVE.................................................................................................................... 77 TRANSMISSION .................................................................................................................................... 78 TRANSMISSION CONTROL VALVE ...................................................................................................................... 86 UPPER VALVE.................................................................................................................................. 87 LOWER VALVE.................................................................................................................................. 88 SOLENOID VALVE............................................................................................................................... 90 EMERGENCY MANUAL SPOOL....................................................................................................................... 91 PRIORITY VALVE............................................................................................................................... 94 MODULATlNG VALVE AND QUICK RETURN VALVE...................................................................................................... 95 ACCUMULATOR VALVE............................................................................................................................ 98 PILOT REDUCING VALVE.........................................................................................................................101 TRANSMISSION PILOT FILTER........................................................................................................................102 TRANSFER ........................................................................................................................................103 DRIVE SHAFT......................................................................................................................................104 AXLE MOUNT.......................................................................................................................................105 AXLE AND DIFFERENTIAL............................................................................................................................107 TORQUE PROPORTIONING DIFFERENTIAL............................................................................................................112 FINAL DRIVE......................................................................................................................................114 TIRE AND WHEEL...................................................................................................................................115 22 TESTING AND ADJUSTING.............................................................................................................................116 STANDARD VALUE TABLE.............................................................................................................................117 TOOL LIST........................................................................................................................................118 ENGINE SPEED.....................................................................................................................................119 OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION................................................................................................121 SHIFT LEVER .....................................................................................................................................123 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL...................................................................................................124 TIRE AND WHEEL...................................................................................................................................126 TROUBLESHOOTING..................................................................................................................................128 PRECAUTIONS WHEN TROUBLESHOOTING.............................................................................................................129 METHOD OF READING TROUBLESHOOTING TABLES.....................................................................................................131 PREVENTING RECURRENCE OF TROUBLE.............................................................................................................133 JUDGEMENT ON POWER TRAIN.....................................................................................................................134 TROUBLESHOOTING TABLE........................................................................................................................137 Machine does not move....................................................................................................................137 Excessive time lag when starting machine or shifting gear................................................................................139 Torque converter oil temperature too high................................................................................................140 23 DISASSEMBLY AND ASSEMBLY..........................................................................................................................142 TORQUE CONVERTER CHARGING PUMP...................................................................................................................144 REMOVAL .....................................................................................................................................144 INSTALLATION.................................................................................................................................145 TORQUE CONVERTER, TRANSMISSION, TRANSFER ........................................................................................................146 REMOVAL......................................................................................................................................146 INSTALLATION.................................................................................................................................153 TORQUE CONVERTER ................................................................................................................................160 DISASSEMBLY..................................................................................................................................160 ASSEMBLY.....................................................................................................................................164 TRANSMISSION.....................................................................................................................................170 DISASSEMBLY..................................................................................................................................170 DISASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER ASSEMBLY.......................................................................................178 DISASSEMBLY OF NO. 3, 4 CARRIER ASSEMBLY.................................................................................................180 DISASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING ASSEMBLY.....................................................................................181 DISASSEMBLY OF NO. 4, 5 HOUSING ASSEMBLY.................................................................................................182 ASSEMBLY.....................................................................................................................................183 ASSEMBLY OF NO. 4, 5 HOUSING ASSEMBLY....................................................................................................183 ASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING ASSEMBLY........................................................................................184 ASSEMBLY OF NO. 3, 4 CARRIER ASSEMBLY....................................................................................................185 ASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER ASSEMBLY..........................................................................................186 ASSEMBLY OF TRANSMISSION.................................................................................................................188 TRANSFER ASSEMBLY ...............................................................................................................................196 DISASSEMBLY..................................................................................................................................196 ASSEMBLY.....................................................................................................................................198 TRANSMISSION CONTROL VALVE.......................................................................................................................204 REMOVAL......................................................................................................................................204 INSTALLATION.................................................................................................................................205 LOWER VALVE..................................................................................................................................206 DISASSEMBLY..............................................................................................................................206 ASSEMBLY.................................................................................................................................206 UPPER VALVE..................................................................................................................................208 DISASSEMBLY..............................................................................................................................208 ASSEMBLY.................................................................................................................................208 FRONT DIFFERENTIAL...............................................................................................................................210 REMOVAL......................................................................................................................................210 INSTALLATION.................................................................................................................................213 REAR DIFFERENTIAL................................................................................................................................216 REMOVAL......................................................................................................................................216 INSTALLATION.................................................................................................................................217 DIFFERENTIAL.....................................................................................................................................218 DISASSEMBLY..................................................................................................................................218 ASSEMBLY.....................................................................................................................................221 FRONT AXLE.......................................................................................................................................229 REMOVAL .....................................................................................................................................229 INSTALLATION.................................................................................................................................232 REAR AXLE........................................................................................................................................234 REMOVAL .....................................................................................................................................234 INSTALLATION.................................................................................................................................238 DRIVE SHAFT......................................................................................................................................242 DISASSEMBLY..................................................................................................................................242 ASSEMBLY.....................................................................................................................................244 FINAL DRIVE......................................................................................................................................246 DISASSEMBLY..................................................................................................................................246 ASSEMBLY.....................................................................................................................................249 24 MAINTENANCE STANDARD..............................................................................................................................254 TRANSMISSION AND ENGINE MOUNT....................................................................................................................255 TORQUE CONVERTER CHARGING PUMP ..................................................................................................................257 TORQUE CONVERTER ................................................................................................................................259 TORQFLOW TRANSMISSION ...........................................................................................................................261 1. TRANSMISSION..............................................................................................................................261 2. TRANSMISSION CONTROL VALVE................................................................................................................265 UPPER VALVE..............................................................................................................................265 LOWER VALVE..............................................................................................................................267 3. SOLENOID VALVE............................................................................................................................269 TRANSFER ........................................................................................................................................271 DIFFERENTIAL.....................................................................................................................................273 FINAL DRIVE .....................................................................................................................................275 DRIVE SHAFT .....................................................................................................................................276 AXLE MOUNT ......................................................................................................................................277 40 STEERING SYSTEM.......................................................................................................................................280 41 STRUCTURE AND FUNCTION............................................................................................................................280 HYDRAULIC PIPING ................................................................................................................................281 HYDRAULIC CIRCUIT DIAGRAMS.......................................................................................................................282 NORMAL STEERING..............................................................................................................................282 GROUND DRIVEN STEERING.......................................................................................................................282 STEERING CONTROL SYSTEM .........................................................................................................................283 STEERING VALVE...............................................................................................................................283 ORBIT-ROLL VALVE.............................................................................................................................284 RELIEF VALVE.................................................................................................................................285 STOP VALVE...................................................................................................................................286 STEERING CYLINDER................................................................................................................................287 STEERING COLUMN AND ORBIT-ROLL ..................................................................................................................288 CENTER HINGE PIN ................................................................................................................................289 GROUND DRIVEN STEERING PUMP (OPTIONAL) ..........................................................................................................290 DIVERTER VALVE (OPTIONAL) .......................................................................................................................291 42 TESTING AND ADJUSTING.............................................................................................................................292 STANDARD VALUE TABLE ............................................................................................................................293 TOOL LIST .......................................................................................................................................293 STEERING WHEEL PLAY .............................................................................................................................294 OPERATING FORCE OF STEERING WHEEL ...............................................................................................................295 OPERATING TIME OF STEERING WHEEL ................................................................................................................296 STEERING CONTROL.................................................................................................................................297 STEERING OIL PRESSURE............................................................................................................................298 GROUND DRIVEN STEERING PUMP......................................................................................................................300 TROUBLESHOOTING..................................................................................................................................302 TROUBLESHOOTING TABLES.......................................................................................................................303 1. Steering wheel does not turn..............................................................................................................303 2. Steering wheel is heavy...................................................................................................................304 3. Steering wheel wobbles or there is excessive shock........................................................................................305 4. Machine steers to one side when traveling.................................................................................................305 5. Turning radius to left and right is different.............................................................................................305 43 DISASSEMBLY AND ASSEMBLY..........................................................................................................................306 STEERING VALVE...................................................................................................................................307 DISASSEMBLY..................................................................................................................................307 ASSEMBLY.....................................................................................................................................310 STEERING DEMAND VALVE............................................................................................................................315 DISASSEMBLY..................................................................................................................................315 ASSEMBLY.....................................................................................................................................319 CENTER HINGE PIN.................................................................................................................................323 REMOVAL......................................................................................................................................323 INSTALLATION.................................................................................................................................332 STEERING CYLINDER................................................................................................................................341 REMOVAL......................................................................................................................................341 INSTALLATION.................................................................................................................................342 DISASSEMBLY..................................................................................................................................343 ASSEMBLY.....................................................................................................................................345 44 MAINTENANCE STANDARD..............................................................................................................................348 STEERING COLUMN AND ORBIT-ROLL...................................................................................................................349 STEERING VALVE...................................................................................................................................350 STEERING CYLINDER MOUNT..........................................................................................................................351 STEERING CYLINDER................................................................................................................................353 CENTER HINGE PIN.................................................................................................................................355 DIVERTER VALVE...................................................................................................................................357 GROUND DRIVEN STEERING PUMP......................................................................................................................359 50 BRAKE AND AIR SYSTEM..................................................................................................................................360 51 STRUCTURE AND FUNCTION............................................................................................................................360 AIR PIPING.......................................................................................................................................361 AIR CIRCUIT DIAGRAM..............................................................................................................................361 AIR TANK.........................................................................................................................................362 WET TANK.....................................................................................................................................362 DRY TANK.....................................................................................................................................363 AIR DRYER........................................................................................................................................364 SAFETY VALVE.....................................................................................................................................367 BRAKE VALVE......................................................................................................................................368 BRAKE ACTUATED...............................................................................................................................369 OPERATING IN BALANCE.........................................................................................................................370 BRAKE RELEASED...............................................................................................................................371 AIR GOVERNOR.....................................................................................................................................372 TWO-WAY VALVE....................................................................................................................................374 BRAKE CHAMBER....................................................................................................................................375 SLACK ADJUSTER...................................................................................................................................377 BRAKE............................................................................................................................................380 PARKING BRAKE....................................................................................................................................382 PARKING BRAKE SOLENOID VALVE.....................................................................................................................384 SPRING CYLINDER..................................................................................................................................385 BRAKE CALIPER....................................................................................................................................386 52 TESTING AND ADJUSTING.............................................................................................................................388 STANDARD VALUE TABLE ............................................................................................................................390 TOOL LIST........................................................................................................................................391 BRAKE PEDAL......................................................................................................................................392 AIR..............................................................................................................................................393 1. Measuring set pressure of air governor....................................................................................................393 2. Measuring cut-off pressure of air pressure alarm buzzer...................................................................................394 3. Measuring safety valve....................................................................................................................395 AIR DRYER........................................................................................................................................396 BRAKE PERFORMANCE................................................................................................................................398 BRAKE OIL PRESSURE...............................................................................................................................399 WEAR OF BRAKE DISC...............................................................................................................................400 AIR BLEEDING FROM BRAKE LINE.....................................................................................................................401 PARKING BRAKE ...................................................................................................................................402 PERFORMANCE..................................................................................................................................402 CHECKING AND ADJUSTING.......................................................................................................................403 TROUBLESHOOTING..................................................................................................................................406 TROUBLESHOOTING TABLES.......................................................................................................................407 1. Air pressure does not rise at all.........................................................................................................407 2. Air pressure does not rise to the specified range.........................................................................................408 3. Brake is ineffective or not very effective................................................................................................409 4. Brake does not release, or drags..........................................................................................................410 5. Parking brake does not release, or drags. (Applies to machines equipped with air parking brake.)..........................................411 6. Air dryer troubleshooting.................................................................................................................412 53 DISASSEMBLY AND ASSEMBLY..........................................................................................................................414 AIR GOVERNOR ....................................................................................................................................416 DISASSEMBLY .................................................................................................................................416 ASSEMBLY.....................................................................................................................................417 AIR DRYER .......................................................................................................................................418 REMOVAL......................................................................................................................................418 INSTALLATION.................................................................................................................................418 DISASSEMBLY..................................................................................................................................420 ASSEMBLY.....................................................................................................................................422 BRAKE VALVE .....................................................................................................................................424 REMOVAL......................................................................................................................................424 INSTALLATION.................................................................................................................................425 DISASSEMBLY..................................................................................................................................426 ASSEMBLY.....................................................................................................................................428 BRAKE CHAMBER ...................................................................................................................................430 REMOVAL......................................................................................................................................430 INSTALLATION.................................................................................................................................432 DISASSEMBLY..................................................................................................................................433 ASSEMBLY.....................................................................................................................................436 SLACK ADJUSTER ..................................................................................................................................440 REMOVAL......................................................................................................................................440 INSTALLATION.................................................................................................................................440 DISASSEMBLY..................................................................................................................................441 ASSEMBLY.....................................................................................................................................442 BRAKE ...........................................................................................................................................443 DISASSEMBLY..................................................................................................................................443 ASSEMBLY.....................................................................................................................................449 SPRING CYLINDER..................................................................................................................................457 REMOVAL......................................................................................................................................457 INSTALLATION.................................................................................................................................458 DISASSEMBLY..................................................................................................................................459 ASSEMBLY.....................................................................................................................................461 PARKING BRAKE ...................................................................................................................................463 REMOVAL......................................................................................................................................463 INSTALLATION.................................................................................................................................465 PARKING BRAKE PAD................................................................................................................................467 REMOVAL .....................................................................................................................................467 INSTALLATION.................................................................................................................................468 54 MAINTENANCE STANDARD..............................................................................................................................470 BRAKE VALVE .....................................................................................................................................471 BRAKE CHAMBER ...................................................................................................................................473 SLACK ADJUSTER ..................................................................................................................................474 BRAKE............................................................................................................................................475 PARKING BRAKE....................................................................................................................................477 SPRING CYLINDER..................................................................................................................................479 60 WORK EQUIPMENT SYSTEM.................................................................................................................................482 61 STRUCTURE AND FUNCTION............................................................................................................................482 HYDRAULIC PIPING.................................................................................................................................483 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................484 FOR 2-SPOOL..................................................................................................................................484 FOR 3-SPOOL..................................................................................................................................485 FOR 3-SPOOL, WITH GROUND DRIVEN STEERING AND SECURITY VALVE..................................................................................486 BUCKET LINKAGE...................................................................................................................................487 BUCKET POSITIONER AND BOOM KICK-OUT..............................................................................................................489 HYDRAULIC TANK...................................................................................................................................491 OIL FILTER BYPASS VALVE......................................................................................................................492 BREATHER.....................................................................................................................................493 HYDRAULIC PUMP...................................................................................................................................494 MAIN CONTROL VALVE...............................................................................................................................495 FOR 2-SPOOL..................................................................................................................................495 FOR 3-SPOOL..................................................................................................................................497 RELIEF VALVE.................................................................................................................................505 SAFETY VALVE (WITH SUCTION VALVE)............................................................................................................506 SUCTION VALVE................................................................................................................................507 HYDRAULIC CYLINDER...............................................................................................................................508 LIFT CYLINDER................................................................................................................................508 DUMP CYLINDER................................................................................................................................509 62 TESTING AND ADJUSTING.............................................................................................................................510 STANDARD VALUE TABLE ............................................................................................................................512 TOOL LIST .......................................................................................................................................513 DUMP AND LIFT CONTROL LEVERS ....................................................................................................................514 HYDRAULIC PRESSURE ..............................................................................................................................516 LIFT ARM AND BUCKET .............................................................................................................................518 HYDRAULIC DRIFT OF LIFT ARM AND BUCKET .........................................................................................................519 BUCKET POSITIONER ...............................................................................................................................520 BOOM KICK-OUT ...................................................................................................................................521 TROUBLESHOOTING..................................................................................................................................522 TROUBLESHOOTING TABLES.......................................................................................................................523 1. Lift arm does not rise....................................................................................................................523 2. Lift arm moves slowly or does not have sufficient lifting power...........................................................................524 3. Lift arm movement becomes slow after it reaches a certain height..........................................................................525 4. Bucket cannot be held down with lift arm cylinder.........................................................................................525 5. Lift arm has large hydraulic drift........................................................................................................525 6. Lift arm movement is unsteady during work.................................................................................................525 7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise"........................................................525 8. Bucket does not tilt back.................................................................................................................526 9. Bucket moves slowly or has insufficient tilt back power...................................................................................527 10. Bucket movement becomes slow during tilt back............................................................................................528 11. Bucket cannot be held down by the bucket cylinder........................................................................................528 12. Bucket has large hydraulic drift.........................................................................................................528 13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")..................................................528 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"........................................................528 15. Control levers of lift arm and dump move stiffly and sluggishly..........................................................................529 63 DISASSEMBLY AND ASSEMBLY..........................................................................................................................530 HYDRAULIC TANK ..................................................................................................................................532 REMOVAL......................................................................................................................................532 INSTALLATION.................................................................................................................................535 HYDRAULIC FILTER ................................................................................................................................538 REMOVAL......................................................................................................................................538 INSTALLATION.................................................................................................................................538 STEERING PUMP....................................................................................................................................539 REMOVAL......................................................................................................................................539 INSTALLATION.................................................................................................................................540 MAIN CONTROL VALVE ..............................................................................................................................541 REMOVAL......................................................................................................................................541 INSTALLATION.................................................................................................................................543 DISASSEMBLY..................................................................................................................................545 ASSEMBLY.....................................................................................................................................547 DUMP CYLINDER ...................................................................................................................................549 REMOVAL......................................................................................................................................549 INSTALLATION.................................................................................................................................551 LIFT CYLINDER....................................................................................................................................552 REMOVAL......................................................................................................................................552 INSTALLATION.................................................................................................................................553 HYDRAULIC CYLINDER...............................................................................................................................554 DISASSEMBLY..................................................................................................................................554 ASSEMBLY.....................................................................................................................................556 WORK EQUIPMENT...................................................................................................................................559 REMOVAL......................................................................................................................................559 lNSTALLATlON.................................................................................................................................562 COUNTERWEIGHT....................................................................................................................................565 REMOVAL......................................................................................................................................565 INSTALLATION.................................................................................................................................565 64 MAINTENANCE STANDARD..............................................................................................................................566 MAIN CONTROL VALVE...............................................................................................................................567 (2 - Spool valve)............................................................................................................................567 (3 - Spool valve)............................................................................................................................569 DUMP CYLINDER....................................................................................................................................571 LIFT CYLINDER....................................................................................................................................572 BUCKET LINKAGE...................................................................................................................................573 BUCKET POSITIONER AND BOOM KICK-OUT..............................................................................................................576 BUCKET...........................................................................................................................................577 HYDRAULIC PUMP...................................................................................................................................578 80 ELECTRIC AND ELECTRONIC SYSTEM........................................................................................................................580 81 STRUCTURE AND FUNCTION............................................................................................................................580 ELECTRICAL WIRING DIAGRAM........................................................................................................................581 ELECTRICAL WIRING 3D CIRCUIT DIAGRAM.............................................................................................................581 ELECTRICAL WIRING CONNECTORS (CN) DIAGRAM........................................................................................................581 ENGINE STARTING CIRCUIT .........................................................................................................................582 ENGINE STOP CIRCUIT..............................................................................................................................584 ELECTRICAL TRANSMISSION CONTROL .................................................................................................................585 COMBINATION SWITCH...........................................................................................................................586 TRANSMISSION CUT-OFF SWITCH..................................................................................................................587 TRANSMISSION CUT-OFF SELECTOR SWITCH.........................................................................................................588 NEUTRALIZER RELAY............................................................................................................................589 KICK-DOWN SWITCH ................................................................................................................................590 KICK-DOWN ELECTRIC CIRCUIT ......................................................................................................................591 ELECTRICAL PARKING BRAKE CONTROL ................................................................................................................597 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) .....................................................................................................606 INDICATION ON MONITOR PANEL..................................................................................................................608 SENSORS......................................................................................................................................610 ENGINE OIL LEVEL SENSOR..................................................................................................................611 COOLANT LEVEL SENSOR.....................................................................................................................611 COOLANT TEMPERATURE SENSOR...............................................................................................................612 TORQUE CONVERTER OIL TEMPERATURE SENSOR..................................................................................................612 PARKING BRAKE SENSOR.....................................................................................................................613 ENGINE OIL PRESSURE SENSOR...............................................................................................................613 BRAKE CHAMBER STROKE SENSOR..............................................................................................................614 AIR PRESSURE SENSOR......................................................................................................................614 ROTATIONAL SPEED SENSOR..................................................................................................................615 FUEL GAUGE SENSOR........................................................................................................................616 WIRING HARNESS...............................................................................................................................617 BUCKET POSITIONER AND BOOM KICK-OUT .............................................................................................................618 82 TESTING AND ADJUSTING.............................................................................................................................624 STANDARD VALUE TABLE ............................................................................................................................627 ADJUSTING SPEEDOMETER MODULE IN THE VEHICLE MONITOR ...........................................................................................630 TROUBLESHOOTING..................................................................................................................................632 CHECKS BEFORE TROUBLESHOOTING................................................................................................................633 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART............................................................................................634 CONNECTOR TERMINAL NUMBERS...................................................................................................................636 PRECAUTION WHEN HANDLING CONNECTOR...........................................................................................................643 ELECTRICAL WIRING (3D) DIAGRAM...............................................................................................................645 ELECTRICAL CONNECTOR (CN) WIRING DIAGRAM.....................................................................................................645 ELECTRICAL CIRCUIT SYSTEM....................................................................................................................646 ENGINE STARTING AND STOP CIRCUIT SYSTEM..................................................................................................646 TRANSMISSION CONTROL, PARKING BRAKE CIRCUIT SYSTEM.......................................................................................647 ETHER INJECTION CIRCUIT SYSTEM...........................................................................................................648 KICK-DOWN CIRCUIT SYSTEM.................................................................................................................649 TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM...................................................................................................650 POSITION OF CONNECTORS FOR TOUBLESHOOTING................................................................................................651 E-1 ENGINE DOES NOT START................................................................................................................655 E-2 ENGINE DOES NOT STOP.................................................................................................................657 E-3 ENGINE STOPS WHEN TRAVELING..........................................................................................................657 E-4 PARKING BRAKE DOES NOT WORK. ........................................................................................................658 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING..............................................................................................659 E-6 PARKING BRAKE IS RELEASED WHEN STARTING .............................................................................................661 E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL. (PARKING BRAKE IS WORKING NORMALLY.) ............................661 E-8 TRANSMISSION DOES NOT WORK NORMALLY. ................................................................................................662 E-9 KICK-DOWN SWITCH DOES NOT WORK. (NORMAL Fl - F4 SWITCHES CORRECTLY) ................................................................683 E-10 KICK-DOWN ONLY IS ON. SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION.) .......................................................686 E-11 KICK-DOWN OPERATION IS NOT CANCELED. ...............................................................................................687 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.....................................................................................689 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED............................................................................689 TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM..............................................................................692 POSITION OF CONNECTORS TROUBLESHOOTING .................................................................................................693 M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS.........................................698 a) None of monitor panel lights up. .................................................................................................698 b) Except for speedometer module, none of monitor panel lights up. ..................................................................698 c) None of CAUTION items light up. ..................................................................................................698 d) Some other parts do not light up..................................................................................................698 M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT. ....................................699 M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT). ...........700 a) (Engine oil level) flashes. ......................................................................................................700 b) (Radiator water level) flashes....................................................................................................701 M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY. (SWITCH POSITIONS ARE NORMAL).............................703 a) (Transmission cut-off) lights up. ................................................................................................703 b) (Parking brake) lights up. .......................................................................................................704 c) (Working lamp) lights up. ........................................................................................................704 M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES. ................................................706 a) Engine oil pressure system. ......................................................................................................706 b) Alternator system. ...............................................................................................................706 M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CAUTION ITEM FLASHES. ...............................................707 a) Engine oil pressure system. ......................................................................................................707 b) Alternator system. ...............................................................................................................707 M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES.................................................709 a) (Charge level) flashes. ..........................................................................................................709 b) (Fuel level) flashes. ............................................................................................................709 c) (Brake line failure) flashes. ....................................................................................................709 d) (Engine oil pressure) flashes. ...................................................................................................709 e) (Radiator water level) flashes. ..................................................................................................709 f) (Air pressure) flashes. ..........................................................................................................710 g) (Engine water temperature) flashes. ..............................................................................................710 h) (Torque converter oil temperature) flashes. ......................................................................................710 M-8 SPEED SENSOR DISPLAY STAYS AT “0”....................................................................................................713 M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY.................................................................................714 a) If high beam does not light up. ..................................................................................................714 b) If high beam lights up when head lamp switch is OFF. (Dimmer switch at Lo position) .............................................714 c) If high beam display lights up when head lamp dimmer switch is at Lo beam position. ..............................................715 M-10 TURN SIGNAL LAMP DOES NOT FLASH. TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING. .............................................716 a) If turn signal lamp does not flash. ..............................................................................................716 b) If turn signal lamp stays ON or does not stop flashing. ..........................................................................716 M-11 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES FOR 1 SEC. CAUTION ITEM IS FLASHING.....................717 M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.................................................................718 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.........719 M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP..............................................................719 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. ....720 a) None of panel lights up. .........................................................................................................720 b) Some of panel lamps do not light up. .............................................................................................720 M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING STAYS ON...........................................721 M-17 SERVICE METER DOES NOT WORK. .......................................................................................................722 M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED. ........................................................................................722 M-19 AIR PRESSURE GAUGE. ................................................................................................................723 a) If nothing is displayed in display area. .........................................................................................723 b) If indicator remains at maximum level. ...........................................................................................723 M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE. .....................................................................................724 a) If nothing is displayed in display area. .........................................................................................724 b) If indicator remains at minimum level. ...........................................................................................724 M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE. .............................................................................725 a) If nothing is displayed in display area. .........................................................................................725 b) If indicator remains at minimum level. ...........................................................................................725 M-22 ABNORMALITY IN FUEL GAUGE. .........................................................................................................726 a) If nothing is displayed in display area. .........................................................................................726 b) If indicator remains at FULL. ....................................................................................................726 83 DISASSEMBLY AND ASSEMBLY..........................................................................................................................728 MACHINE MONITOR ................................................................................................................................729 REMOVAL......................................................................................................................................729 INSTALLATION.................................................................................................................................729 90 OTHER.................................................................................................................................................730 93 DISASSEMBLY AND ASSEMBLY..........................................................................................................................730 CAB..............................................................................................................................................731 REMOVAL......................................................................................................................................731 INSTALLATION.................................................................................................................................731 97 GEAR PUMP.........................................................................................................................................732 GENERAL..........................................................................................................................................733 PRINCIPLE OF OPERATION.......................................................................................................................734 PRESSURE LOADED TYPE GEAR PUMP...............................................................................................................737 FIXED SIDE PLATE TYPE GEAR PUMP..............................................................................................................739 SA SERIES........................................................................................................................................740 STRUCTURE....................................................................................................................................740 TESTING AND ADJUSTING........................................................................................................................744 DISASSEMBLY..................................................................................................................................747 ASSEMBLY.....................................................................................................................................751 MAINTENANCE STANDARD.........................................................................................................................756 99 METRIC CONVERSIONS................................................................................................................................758
KOMATSU WA420-1LC WHEEL LOADER SHOP MANUAL A25001 AND UP – PDF DOWNLOAD:
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