Komatsu WA450-3 WHEEL LOADER Shop Manual SEBM015501 – PDF DOWNLOAD

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Komatsu WA450-3 WHEEL LOADER Shop Manual SEBM015501 – PDF DOWNLOAD

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Komatsu WA450-3 WHEEL LOADER Shop Manual SEBM015501 – PDF DOWNLOAD

Language : English
Pages :769
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA450-3 WHEEL LOADER Shop Manual SEBM015501 – PDF DOWNLOAD

FOREWORD
GENERAL
FOREWORD 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 chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu WA450-3 WHEEL LOADER Shop Manual SEBM015501 – PDF DOWNLOAD

MAIN MENU 0
CONTENTS 2
01 GENERAL 25
GENERAL ASSEMBLY DRAWING 26
SPECIFICATIONS 27
WEIGHT TABLE 30
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 34
POWER TRAIN 35
POWER TRAIN SYSTEM 36
TORQUE CONVERTER, TRANSMISSION PIPING 38
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 39
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 40
TORQUE CONVERTER 41
TORQUE CONVERTER OIL FILTER 44
TRANSMISSION 45
TRANSMISSION CONTROL VALVE 56
PROPORTIONAL SOLENOID VALVE 71
ELECTRONIC CONTROL MODULATION VALVE 72
PILOT OIL FILTER 75
DRIVE SHAFT 76
AXLE 77
DIFFERENTIAL 79
FINAL DRIVE 83
AXLE MOUNT, CENTER HINGE PIN 84
STEERING PIPING 85
STEERING COLUMN 86
STEERING VALVE 87
ORBIT-ROLL VALVE 101
STOP VALVE 105
EMERGENCY STEERING PUMP 106
DIVERTER VALVE 107
BRAKE PIPING 110
BRAKE CIRCUIT DIAGRAM 112
BRAKE VALVE114
CHARGE VALVE 119
ACCUMULATOR (FOR BRAKE) 123
SLACK ADJUSTER 124
BRAKE127
PARKING BRAKE CONTROL 129
PARKING BRAKE 130
PARKING BRAKE SOLENOID VALVE 131
PARKING BRAKE VALVE 132
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE 133
HYDRAULIC PIPING 134
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 136
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 137
WORK EQUIPMENT LEVER LINKAGE 139
HYDRAULIC TANK 140
PPC VALVE142
PPC RELIEF VALVE 147
ACCUMULATOR (FOR PPC VALVE) 148
CUT-OFF VALVE 149
MAIN CONTROL VALVE 152
WORK EQUIPMENT LINKAGE 166
BUCKET 168
BUCKET POSITIONER AND BOOM KICK-OUT 169
ROPS CAB 175
HEATER AND DEFROSTER 176
AIR CONDITIONER (OPTION) 177
ELECTRIC CIRCUIT DIAGRAM178
MACHINE MONITOR SYSTEM 183
MAIN MONITOR 184
MAINTENANCE MONITOR 189
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 191
SENSORS 197
ENGINE STARTING CIRCUIT 202
ENGINE STOP CIRCUIT 203
PREHEATING CIRCUIT 204
ELECTRIC TRANSMISSION CONTROL 205
KICK-DOWN, HOLD SWITCH 208
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 209
TRANSMISSION CUT-OFF SWITCH 213
TRANSMISSION CUT-OFF FUNCTION 214
ELECTRIC PARKING BRAKE CONTROL 216
20 TESTING AND ADJUSTING228
STANDARD VALUE TABLE229
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS229
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS230
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 233
TESTING AND ADJUSTING236
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING237
MEASURING ENGINE SPEED238
MEASURING INTAKE AIR PRESSURE239
ADJUSTING VALVE CLEARANCE240
MEASURING EXHAUST GAS COLOR241
MEASURING EXHAUST GAS TEMPERATURE242
MEASURING BLOW-BY PRESSURE243
MEASURING COMPRESSION PRESSURE244
MEASURING ENGINE OIL PRESSURE245
TESTING AND ADJUSTING FUEL INJECTION TIMING246
ADJUSTING ENGINE STOP MOTOR CABLE249
TESTING AND ADJUSTING FAN BELT TENSION251
TESTING ACCELERATOR PEDAL252
TESTING SPEED CONTROL LEVER254
MEASURING STALL SPEED255
MEASURING TORQUE CONVERTER, TRANSMISSION, AND PARKING BRAKE OIL PRESSURE257
METHOD OF OPERATING EMERGENCY MANUAL SPOOL259
TESTING AND ADJUSTING STEERING WHEEL261
TESTING AND ADJUSTING STEERING CONTROL264
TESTING AND ADJUSTING STEERING OIL PRESSURE265
TESTING BRAKE PEDAL267
TESTING BRAKE OIL PRESSURE268
MEASURING BRAKE PERFORMANCE269
MEASURING BRAKE DISC WEAR270
BLEEDING AIR FROM BRAKE SYSTEM271
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE272
MEASURING PARKING BRAKE PERFORMANCE273
MANUAL RELEASE OF PARKING BRAKE274
TESTING WEAR OF PARKING BRAKE DISC275
TESTING WORK EQUIPMENT CONTROL LEVER276
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE278
TESTING WORK EQUIPMENT282
TESTING AND ADJUSTING BUCKET POSITIONER284
TESTING AND ADJUSTING BOOM KICK-OUT285
ADJUSTING MAIN MONITOR287
TESTING FUEL LEVEL SENSOR288
TROUBLESHOOTING289
POINTS TO REMEMBER WHEN TROUBLESHOOTING 290
SEQUENCE OF EVENTS IN TROUBLESHOOTING 291
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE292
CHECKS BEFORE TROUBLESHOOTING 300
METHOD OF USING TROUBLESHOOTING CHARTS 301
CONNECTOR TYPES AND MOUNTING LOCATIONS 309
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS316
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)326
S-1 Starting performance is poor327
S-2 Engine does not start328
(1) Engine does not turn328
(2) Engine turns but no exhaust gas comes out329
(3) Exhaust gas comes out but engine does not start330
S-3 Engine does not pick up smoothly331
S-4 Engine stops during operations332
S-5 Engine does not rotate smoothly333
S-6 Engine lacks power334
S-7 Exhaust gas is black335
S-8 Oil consumption is excessive or exhaust gas is blue336
S-9 Oil becomes contaminated quickly337
S-10 Fuel consumption is excessive338
S-11 Oil is in cooling water, or water spurts or water level goes down339
S-12 Oil pressure lamp lights up340
S-13 Oil level rises341
S-14 Water temperature becomes too high342
S-15 Abnormal noise is made343
S-16 Vibration is excessive344
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)345
FAILURE CODE347
M-1 Main monitor does not work350
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up351
M-3 Speedometer display does not work properly352
M-4 Abnormality in shift indicator353
(a) Stays at N even when directional lever is at F353
(b) Stays at N even when directional lever is at R353
(c) Does not display N even when directional lever is at N and displays R when directional lever is at F353
(d) Does not display N even when directional lever is at N and displays F when directional lever is at R354
(e) Does not display 1st, 4th354
(f) Does not display 3rd, 4th354
M-5 High beam does not light up356
M-6 Turn signal display does not light up357
(a) LH turn signal does not light up357
(b) RH turn signal does not light up357
M-7 Abnormality in parking display358
(a) Parking lamp does not light up358
(b) Parking lamp stays lighted up358
M-8 Abnormality in preheating system359
(a) Does not carry out preheating359
(b) Always carries out preheating for 1 minute360
(c) Preheating stays on360
(d) Preheating time becomes shorter, or there is fluctuation361
M-9 Night lighting does not light up362
M-10 Abnormality in front working lamp363
(a) Neither monitor display nor front working lamp light up363
(b) Working lamp lights up but monitor display does not light up363
(c) Monitor lights up but working lamp does not light up363
M-11 Abnormality in rear working lamp364
(a) Neither monitor display nor rear working lamp light up364
(b) Working lamp lights up but monitor display does not light up364
(c) Monitor lights up but working lamp does not light up364
M-12 Abnormality in transmission cut-off366
(a) When monitor switch is pressed, transmission cut-off function is not actuated and display goes out366
(b) Monitor display goes out but transmission cut-off function is actuated when left brake pedal is depressed366
(c) Monitor display goes out but transmission cut-off function is always actuated366
(d) Cut-off function is always actuated regardless of monitor display366
(e) Monitor display lights up but cut-off function is not actuated367
M-13 Abnormality in parking brake dragging warning368
(a) When parking brake is applied, buzzer sounds intermittently even when directional lever is at N, and caution lamp flashes368
(b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at po368
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated369
(a) Actuated continuously369
(b) Not actuated369
M-15 Abnormality in buzzer370
(a) Buzzer does not sound for 3 seconds when starting switch is turned ON370
(b) Buzzer always sounds370
M-16 Condition of monitor switches is not stored in memory371
M-17 Abnormality in failure display mode372
(a) Failure display mode does not work372
(b) Time elapsed since failure does not advance372
M-18 Abnormality in emergency steering normal display373
(a) Emergency steering normal display does not light up373
(b) Emergency steering normal display stays lighted up373
M-19 Abnormality in emergency steering actuation display374
(a) Emergency steering actuation display does not light up374
(b) Emergency steering actuation display stays lighted up374
M-20 Abnormality in auto-greasing375
(a) Forced greasing cannot be carried out375
(b) Monitor display flashes rapidly (2 times/sec)375
(c) When no more grease remains, monitor display flashes rapidly (2 times/sec)375
(d) Monitor display flashes slowly (1 time/set)376
(e) Monitor display goes out376
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)377
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does 378
(a) All lamps on maintenance monitor do not light up for 3 seconds378
(b) Some lamps do not light up379
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out379
K-3 When engine is started immediately after starting switch is turned ON, all lamps on maintenance monitor do not go out380
K-4 When starting switch is turned ON (engine stopped), CHECK items flash381
(a) Engine oil level display flashes381
(b) Engine water level display flashes382
K-5 When starting switch is turned ON (engine started), CAUTION items flash383
(a) Engine oil pressure display flashes383
(b) Battery charge level display flashes384
(c) Brake oil pressure display flashes385
(d) Air cleaner display flashes386
K-6 CAUTION items are flashing but alarm buzzer does not sound387
K-7 There is no abnormality in monitor display but alarm buzzer sounds388
K-8 CHECK items or CAUTION items are flashing but CHECK lamp or CAUTION lamp does not light up389
(a) CHECK lamp389
(b) CAUTION lamp389
K-9 There is no abnormality in maintenance monitor display but CHECK lamp or CAUTION lamp lights up390
(a) CHECK lamp390
(b) CAUTION lamp390
K-10 Night lighting does not light up when lamp switch is turned ON391
K-11 Night lighting lights up even when lamp switch is OFF392
K-12 Service meter does not work393
K-13 Service meter is running even when engine is stopped393
K-14 Abnormality in gauge394
(a) Abnormality in fuel gauge394
(b) Abnormality in engine water temperature gauge395
(c) Abnormality in torque converter oil temperature gauge396
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)397
E-1 Engine does not start398
(a) Starting motor does not turn398
(b) Starting motor turns402
E-2 Engine does not stop404
E-3 Engine stops when machine is traveling404
E-4 Parking brake does not work405
(a) Parking brake has no effect when parking brake switch is turned ON405
(b) Parking brake has no effect when brake pressure drops405
E-5 Parking brake is applied when machine is traveling406
E-6 Parking brake is released when starting switch is turned ON408
E-7 Transmission does not change to neutral when parking brake is applied408
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)409
1 Function410
2 When carrying out troubleshooting410
3 Failure code410
4 Table of failure modes and causes411
A-1 Failure code [10] Modulation valve solenoid system412
A-2 Failure code [11] Short circuit in power supply for modulation valve solenoid system413
A-3 Failure code [12] F solenoid signal system414
A-4 Failure code [13] R solenoid signal system414
A-5 Failure code [14] Abnormality in H-L solenoid signal system415
A-6 Failure code [16] Abnormality in speed solenoid signal system416
A-7 Failure code [17] Brake output signal system417
A-8 Failure code [20] Abnormality in directional lever signal system418
A-9 Failure code [21] Abnormality in speed lever signal system419
A-10 Failure code [22] Abnormality in travel speed signal system420
A-11 Failure code [23] Abnormality in engine speed signal421
A-12 Hold switch system422
A-13 Kick-down switch system422
A-14 Transmission cut-off signal system423
A-15 Neutralizer signal system424
A-16 Buzzer signal system425
A-17 Network signal system426
A-18 Controller power supply system427
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE)428
T-1 Machine does not start429
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes 431
T-3 Excessive shock when starting machine or shifting gear433
T-4 Excessive time lag when starting machine or shifting gear434
T-5 Torque converter oil temperature is high 435
T-6 Steering does not turn 436
T-7 Steering wheel is heavy 437
T-8 Steering wheel shakes or jerks 438
T-9 Machine deviates to one side when traveling 438
T-10 Turning radius is different between left and right 438
T-11 Brakes do not work or braking effect is poor 439
T-12 Brakes are not released or brakes drag 440
T-13 Parking brake is not released or brake drags 441
T-14 Lift arm does not rise 442
T-15 Lift arm movement is slow or lift arm lacks lifting power 443
T-16 When lift arm is raised, it moves slowly at a certain height 444
T-17 Bucket cannot be pushed with lift cylinder 444
T-18 Excessive hydraulic drift of lift arm 444
T-19 Lift arm shakes during operation 444
T-20 Lift arm drops momentarily when control lever is operated from HOLD to RAISE 445
T-21 Bucket does not tilt back446
T-22 Bucket movement is slow or tilt-back lacks power447
T-23 Bucket movement is slow during tilt-back operation 448
T-24 Bucket cannot be pushed with dump cylinder 448
T-25 Excessive hydraulic drift of bucket 448
T-26 Bucket shakes during loading operation 449
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT 449
T-28 Work equipment control levers are heavy or do not move smoothly450
30 DISASSEMBLY AND ASSEMBLY451
METHOD OF USING MANUAL 453
PRECAUTIONS WHEN CARRYING OUT OPERATION 454
SPECIAL TOOL LIST 456
STARTING MOTOR458
REMOVAL458
INSTALLATION 458
ALTERNATOR 459
REMOVAL459
INSTALLATION459
ENGINE OIL COOLER460
REMOVAL460
INSTALLATION 460
FUEL INJECTION PUMP461
REMOVAL461
INSTALLATION462
WATER PUMP463
REMOVAL463
INSTALLATION463
TURBOCHARGER464
REMOVAL464
INSTALLATION464
NOZZLE HOLDER465
REMOVAL465
INSTALLATION465
THERMOSTAT 466
REMOVAL466
INSTALLATION 466
CYLINDER HEAD467
REMOVAL467
INSTALLATION471
RADIATOR 473
REMOVAL473
INSTALLATION475
ENGINE476
REMOVAL476
INSTALLATION481
TORQUE CONVERTER, TRANSMISSION 483
REMOVAL483
INSTALLATION 490
TORQUE CONVERTER492
DISASSEMBLY492
ASSEMBLY494
TRANSMISSION497
DISASSEMBLY497
ASSEMBLY502
TRANSMISSION CLUTCH PACK 508
DISASSEMBLY508
ASSEMBLY517
PARKING BRAKE529
DISASSEMBLY529
ASSEMBLY 531
TRANSMISSION CONTROL VALVE 534
REMOVAL534
INSTALLATION536
DISASSEMBLY 537
ASSEMBLY542
TRANSMISSION ACCUMULATOR VALVE548
DISASSEMBLY548
ASSEMBLY549
DRIVE SHAFT 550
DISASSEMBLY550
ASSEMBLY 552
FRONT AXLE 554
REMOVAL554
INSTALLATION 556
REAR AXLE557
REMOVAL557
INSTALLATION560
FRONT DIFFERENTIAL562
REMOVAL562
INSTALLATION565
REAR DIFFERENTIAL 567
REMOVAL567
INSTALLATION 570
DIFFERENTIAL572
DISASSEMBLY572
ASSEMBLY 575
FINAL DRIVE583
DISASSEMBLY583
ASSEMBLY586
CENTER HINGE PIN 590
REMOVAL590
INSTALLATION599
STEERING VALVE (ORBIT ROLL) 605
REMOVAL605
INSTALLATION606
STEERING VALVE 607
DISASSEMBLY607
ASSEMBLY610
REMOVAL 615
INSTALLATION 616
STEERING DEMAND VALVE 617
DISASSEMBLY617
ASSEMBLY 621
STEERING, SWITCH PUMP625
REMOVAL625
INSTALLATION628
STEERING CYLINDER629
REMOVAL629
INSTALLATION630
BRAKE VALVE631
REMOVAL631
INSTALLATION 632
RIGHT BRAKE VALVE (TANDEM) 633
DISASSEMBLY633
ASSEMBLY 634
LEFT BRAKE VALVE (SINGLE) 635
DISASSEMBLY635
ASSEMBLY636
SLACK ADJUSTER637
REMOVAL637
INSTALLATION 638
DISASSEMBLY 639
ASSEMBLY 640
BRAKE641
DISASSEMBLY641
ASSEMBLY647
PARKING BRAKE DISC 655
REMOVAL655
INSTALLATION 657
ACCUMULATOR CHARGE VALVE658
REMOVAL658
INSTALLATION 658
DISASSEMBLY659
ASSEMBLY661
HYDRAULIC TANK663
REMOVAL663
INSTALLATION665
WORK EQUIPMENT, PPC PUMP666
REMOVAL666
INSTALLATION669
PPC VALVE 670
REMOVAL670
INSTALLATION671
DISASSEMBLY672
ASSEMBLY673
MAIN CONTROL VALVE 674
REMOVAL674
INSTALLATION676
DISASSEMBLY 677
ASSEMBLY 679
DUMP CYLINDER681
REMOVAL681
INSTALLATION 682
LIFT CYLINDER 683
REMOVAL683
INSTALLATION 684
HYDRAULIC CYLINDER685
DISASSEMBLY685
ASSEMBLY688
WORK EQUIPMENT 691
REMOVAL691
INSTALLATION694
COUNTERWEIGHT 696
REMOVAL696
INSTALLATION696
FUEL TANK 697
REMOVAL697
INSTALLATION 698
CAB699
REMOVAL699
INSTALLATION700
MAIN MONITOR 701
REMOVAL701
INSTALLATION702
MAINTENANCE MONITOR 703
REMOVAL703
INSTALLATION703
AIR CONDITIONER UNIT704
REMOVAL704
INSTALLATION 709
AIR CONDITIONER CONDENSER 710
REMOVAL710
INSTALLATION711
DRY RECEIVER712
REMOVAL712
INSTALLATION712
AIR CONDITIONER COMPRESSOR713
REMOVAL713
INSTALLATION 714
40 MAINTENANCE STANDARD715
ENGINE MOUNT, TRANSMISSION MOUNT 716
TORQUE CONVERTER 717
TRANSMISSION718
TRANSMISSION CONTROL VALVE 725
DRIVE SHAFT 732
DIFFERENTIAL 733
FINAL DRIVE 735
AXLE MOUNT 736
STEERING COLUMN 737
STEERING VALVE 738
STEERING CYLINDER MOUNT 739
SLACK ADJUSTER 740
BRAKE VALVE 741
BRAKE744
PARKING BRAKE746
TORQUE CONVERTER, TRANSMISSION PUMP 747
STEERING, SWITCH PUMP 748
HYDRAULIC, PPC PUMP 749
PPC VALVE 750
CUT-OFF VALVE 751
MAIN CONTROL VALVE 752
LIFT CYLINDER 756
DUMP CYLINDER 757
CENTER HINGE PIN 758
WORK EQUIPMENT LINKAGE 760
BUCKET 762
BUCKET POSITIONER AND BOOM KICK-OUT 763
90 OTHERS764
ELECTRIC CIRCUIT DIAGRAM (1/4)765
ELECTRIC CIRCUIT DIAGRAM (2/4)766
ELECTRIC CIRCUIT DIAGRAM (3/4)767
ELECTRIC CIRCUIT DIAGRAM (4/4)768

IMAGES PREVIEW OF THE MANUAL:

S.M 12/12/24