Komatsu WA420LC-Series Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA420LC.zip

This is a full factory-style service and repair guide, complete with Electrical Wiring Diagrams, covering the Komatsu WA420LC-Series Wheel Loader. Inside, you'll find every technical detail needed to service, troubleshoot, fix, and overhaul the machine the way professional technicians do.

What's contained in the Komatsu WA420LC-Series Wheel Loader workshop service and repair manual:

* 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