Komatsu WA450-3 Wheel Loader Shop Manual SEBM015501 PDF

Description

Komatsu WA450-3 Wheel Loader Shop Manual SEBM015501 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA450-3 Wheel Loader Shop Manual SEBM015501 – PDF DOWNLOAD 

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

IMAGES PREVIEW OF THE MANUAL:

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 VALVE 114
CHARGE VALVE 119
ACCUMULATOR (FOR BRAKE) 123
SLACK ADJUSTER 124
BRAKE 127
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 VALVE 142
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 DIAGRAM 178
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 ADJUSTING 228
STANDARD VALUE TABLE 229
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 229
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 230
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 233
TESTING AND ADJUSTING 236
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 237
MEASURING ENGINE SPEED 238
MEASURING INTAKE AIR PRESSURE 239
ADJUSTING VALVE CLEARANCE 240
MEASURING EXHAUST GAS COLOR 241
MEASURING EXHAUST GAS TEMPERATURE 242
MEASURING BLOW-BY PRESSURE 243
MEASURING COMPRESSION PRESSURE 244
MEASURING ENGINE OIL PRESSURE 245
TESTING AND ADJUSTING FUEL INJECTION TIMING 246
ADJUSTING ENGINE STOP MOTOR CABLE 249
TESTING AND ADJUSTING FAN BELT TENSION 251
TESTING ACCELERATOR PEDAL 252
TESTING SPEED CONTROL LEVER 254
MEASURING STALL SPEED 255
MEASURING TORQUE CONVERTER, TRANSMISSION, AND PARKING BRAKE OIL PRESSURE 257
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 259
TESTING AND ADJUSTING STEERING WHEEL 261
TESTING AND ADJUSTING STEERING CONTROL 264
TESTING AND ADJUSTING STEERING OIL PRESSURE 265
TESTING BRAKE PEDAL 267
TESTING BRAKE OIL PRESSURE 268
MEASURING BRAKE PERFORMANCE 269
MEASURING BRAKE DISC WEAR 270
BLEEDING AIR FROM BRAKE SYSTEM 271
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 272
MEASURING PARKING BRAKE PERFORMANCE 273
MANUAL RELEASE OF PARKING BRAKE 274
TESTING WEAR OF PARKING BRAKE DISC 275
TESTING WORK EQUIPMENT CONTROL LEVER 276
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 278
TESTING WORK EQUIPMENT 282
TESTING AND ADJUSTING BUCKET POSITIONER 284
TESTING AND ADJUSTING BOOM KICK-OUT 285
ADJUSTING MAIN MONITOR 287
TESTING FUEL LEVEL SENSOR 288
TROUBLESHOOTING 289
POINTS TO REMEMBER WHEN TROUBLESHOOTING 290
SEQUENCE OF EVENTS IN TROUBLESHOOTING 291
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 292
CHECKS BEFORE TROUBLESHOOTING 300
METHOD OF USING TROUBLESHOOTING CHARTS 301
CONNECTOR TYPES AND MOUNTING LOCATIONS 309
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 316
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 326
S-1 Starting performance is poor 327
S-2 Engine does not start 328
(1) Engine does not turn 328
(2) Engine turns but no exhaust gas comes out 329
(3) Exhaust gas comes out but engine does not start 330
S-3 Engine does not pick up smoothly 331
S-4 Engine stops during operations 332
S-5 Engine does not rotate smoothly 333
S-6 Engine lacks power 334
S-7 Exhaust gas is black 335
S-8 Oil consumption is excessive or exhaust gas is blue 336
S-9 Oil becomes contaminated quickly 337
S-10 Fuel consumption is excessive 338
S-11 Oil is in cooling water, or water spurts or water level goes down 339
S-12 Oil pressure lamp lights up 340
S-13 Oil level rises 341
S-14 Water temperature becomes too high 342
S-15 Abnormal noise is made 343
S-16 Vibration is excessive 344
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 345
FAILURE CODE 347
M-1 Main monitor does not work 350
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up 351
M-3 Speedometer display does not work properly 352
M-4 Abnormality in shift indicator 353
(a) Stays at N even when directional lever is at F 353
(b) Stays at N even when directional lever is at R 353
(c) Does not display N even when directional lever is at N and displays R when directional lever is at F 353
(d) Does not display N even when directional lever is at N and displays F when directional lever is at R 354
(e) Does not display 1st, 4th 354
(f) Does not display 3rd, 4th 354
M-5 High beam does not light up 356
M-6 Turn signal display does not light up 357
(a) L H turn signal does not light up 357
(b) R H turn signal does not light up 357
M-7 Abnormality in parking display 358
(a) Parking lamp does not light up 358
(b) Parking lamp stays lighted up 358
M-8 Abnormality in preheating system 359
(a) Does not carry out preheating 359
(b) Always carries out preheating for 1 minute 360
(c) Preheating stays on 360
(d) Preheating time becomes shorter, or there is fluctuation 361
M-9 Night lighting does not light up 362
M-10 Abnormality in front working lamp 363
(a) Neither monitor display nor front working lamp light up 363
(b) Working lamp lights up but monitor display does not light up 363
(c) Monitor lights up but working lamp does not light up 363
M-11 Abnormality in rear working lamp 364
(a) Neither monitor display nor rear working lamp light up 364
(b) Working lamp lights up but monitor display does not light up 364
(c) Monitor lights up but working lamp does not light up 364
M-12 Abnormality in transmission cut-off 366
(a) When monitor switch is pressed, transmission cut-off function is not actuated and display goes out 366
(b) Monitor display goes out but transmission cut-off function is actuated when left brake pedal is depressed 366
(c) Monitor display goes out but transmission cut-off function is always actuated 366
(d) Cut-off function is always actuated regardless of monitor display 366
(e) Monitor display lights up but cut-off function is not actuated 367
M-13 Abnormality in parking brake dragging warning 368
(a) When parking brake is applied, buzzer sounds intermittently even when directional lever is at N, and caution lamp flashes 368
(b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at po 368
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated 369
(a) Actuated continuously 369
(b) Not actuated 369
M-15 Abnormality in buzzer 370
(a) Buzzer does not sound for 3 seconds when starting switch is turned ON 370
(b) Buzzer always sounds 370
M-16 Condition of monitor switches is not stored in memory 371
M-17 Abnormality in failure display mode 372
(a) Failure display mode does not work 372
(b) Time elapsed since failure does not advance 372
M-18 Abnormality in emergency steering normal display 373
(a) Emergency steering normal display does not light up 373
(b) Emergency steering normal display stays lighted up 373
M-19 Abnormality in emergency steering actuation display 374
(a) Emergency steering actuation display does not light up 374
(b) Emergency steering actuation display stays lighted up 374
M-20 Abnormality in auto-greasing 375
(a) Forced greasing cannot be carried out 375
(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 out 376
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 seconds 378
(b) Some lamps do not light up 379
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out 379
K-3 When engine is started immediately after starting switch is turned ON, all lamps on maintenance monitor do not go out 380
K-4 When starting switch is turned ON (engine stopped), CHECK items flash 381
(a) Engine oil level display flashes 381
(b) Engine water level display flashes 382
K-5 When starting switch is turned ON (engine started), CAUTION items flash 383
(a) Engine oil pressure display flashes 383
(b) Battery charge level display flashes 384
(c) Brake oil pressure display flashes 385
(d) Air cleaner display flashes 386
K-6 CAUTION items are flashing but alarm buzzer does not sound 387
K-7 There is no abnormality in monitor display but alarm buzzer sounds 388
K-8 CHECK items or CAUTION items are flashing but CHECK lamp or CAUTION lamp does not light up 389
(a) CHECK lamp 389
(b) CAUTION lamp 389
K-9 There is no abnormality in maintenance monitor display but CHECK lamp or CAUTION lamp lights up 390
(a) CHECK lamp 390
(b) CAUTION lamp 390
K-10 Night lighting does not light up when lamp switch is turned ON 391
K-11 Night lighting lights up even when lamp switch is OFF 392
K-12 Service meter does not work 393
K-13 Service meter is running even when engine is stopped 393
K-14 Abnormality in gauge 394
(a) Abnormality in fuel gauge 394
(b) Abnormality in engine water temperature gauge 395
(c) Abnormality in torque converter oil temperature gauge 396
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 397
E-1 Engine does not start 398
(a) Starting motor does not turn 398
(b) Starting motor turns 402
E-2 Engine does not stop 404
E-3 Engine stops when machine is traveling 404
E-4 Parking brake does not work 405
(a) Parking brake has no effect when parking brake switch is turned ON 405
(b) Parking brake has no effect when brake pressure drops 405
E-5 Parking brake is applied when machine is traveling 406
E-6 Parking brake is released when starting switch is turned ON 408
E-7 Transmission does not change to neutral when parking brake is applied 408
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE) 409
1 Function 410
2 When carrying out troubleshooting 410
3 Failure code 410
4 Table of failure modes and causes 411
A-1 Failure code [10] Modulation valve solenoid system 412
A-2 Failure code [11] Short circuit in power supply for modulation valve solenoid system 413
A-3 Failure code [12] F solenoid signal system 414
A-4 Failure code [13] R solenoid signal system 414
A-5 Failure code [14] Abnormality in H-L solenoid signal system 415
A-6 Failure code [16] Abnormality in speed solenoid signal system 416
A-7 Failure code [17] Brake output signal system 417
A-8 Failure code [20] Abnormality in directional lever signal system 418
A-9 Failure code [21] Abnormality in speed lever signal system 419
A-10 Failure code [22] Abnormality in travel speed signal system 420
A-11 Failure code [23] Abnormality in engine speed signal 421
A-12 Hold switch system 422
A-13 Kick-down switch system 422
A-14 Transmission cut-off signal system 423
A-15 Neutralizer signal system 424
A-16 Buzzer signal system 425
A-17 Network signal system 426
A-18 Controller power supply system 427
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE) 428
T-1 Machine does not start 429
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes 431
T-3 Excessive shock when starting machine or shifting gear 433
T-4 Excessive time lag when starting machine or shifting gear 434
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 back 446
T-22 Bucket movement is slow or tilt-back lacks power 447
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 smoothly 450
30 DISASSEMBLY AND ASSEMBLY 451
METHOD OF USING MANUAL 453
PRECAUTIONS WHEN CARRYING OUT OPERATION 454
SPECIAL TOOL LIST 456
STARTING MOTOR 458
REMOVAL 458
INSTALLATION 458
ALTERNATOR 459
REMOVAL 459
INSTALLATION 459
ENGINE OIL COOLER 460
REMOVAL 460
INSTALLATION 460
FUEL INJECTION PUMP 461
REMOVAL 461
INSTALLATION 462
WATER PUMP 463
REMOVAL 463
INSTALLATION 463
TURBOCHARGER 464
REMOVAL 464
INSTALLATION 464
NOZZLE HOLDER 465
REMOVAL 465
INSTALLATION 465
THERMOSTAT 466
REMOVAL 466
INSTALLATION 466
CYLINDER HEAD 467
REMOVAL 467
INSTALLATION 471
RADIATOR 473
REMOVAL 473
INSTALLATION 475
ENGINE 476
REMOVAL 476
INSTALLATION 481
TORQUE CONVERTER, TRANSMISSION 483
REMOVAL 483
INSTALLATION 490
TORQUE CONVERTER 492
DISASSEMBLY 492
ASSEMBLY 494
TRANSMISSION 497
DISASSEMBLY 497
ASSEMBLY 502
TRANSMISSION CLUTCH PACK 508
DISASSEMBLY 508
ASSEMBLY 517
PARKING BRAKE 529
DISASSEMBLY 529
ASSEMBLY 531
TRANSMISSION CONTROL VALVE 534
REMOVAL 534
INSTALLATION 536
DISASSEMBLY 537
ASSEMBLY 542
TRANSMISSION ACCUMULATOR VALVE 548
DISASSEMBLY 548
ASSEMBLY 549
DRIVE SHAFT 550
DISASSEMBLY 550
ASSEMBLY 552
FRONT AXLE 554
REMOVAL 554
INSTALLATION 556
REAR AXLE 557
REMOVAL 557
INSTALLATION 560
FRONT DIFFERENTIAL 562
REMOVAL 562
INSTALLATION 565
REAR DIFFERENTIAL 567
REMOVAL 567
INSTALLATION 570
DIFFERENTIAL 572
DISASSEMBLY 572
ASSEMBLY 575
FINAL DRIVE 583
DISASSEMBLY 583
ASSEMBLY 586
CENTER HINGE PIN 590
REMOVAL 590
INSTALLATION 599
STEERING VALVE (ORBIT ROLL) 605
REMOVAL 605
INSTALLATION 606
STEERING VALVE 607
DISASSEMBLY 607
ASSEMBLY 610
REMOVAL 615
INSTALLATION 616
STEERING DEMAND VALVE 617
DISASSEMBLY 617
ASSEMBLY 621
STEERING, SWITCH PUMP 625
REMOVAL 625
INSTALLATION 628
STEERING CYLINDER 629
REMOVAL 629
INSTALLATION 630
BRAKE VALVE 631
REMOVAL 631
INSTALLATION 632
RIGHT BRAKE VALVE (TANDEM) 633
DISASSEMBLY 633
ASSEMBLY 634
LEFT BRAKE VALVE (SINGLE) 635
DISASSEMBLY 635
ASSEMBLY 636
SLACK ADJUSTER 637
REMOVAL 637
INSTALLATION 638
DISASSEMBLY 639
ASSEMBLY 640
BRAKE 641
DISASSEMBLY 641
ASSEMBLY 647
PARKING BRAKE DISC 655
REMOVAL 655
INSTALLATION 657
ACCUMULATOR CHARGE VALVE 658
REMOVAL 658
INSTALLATION 658
DISASSEMBLY 659
ASSEMBLY 661
HYDRAULIC TANK 663
REMOVAL 663
INSTALLATION 665
WORK EQUIPMENT, PPC PUMP 666
REMOVAL 666
INSTALLATION 669
PPC VALVE 670
REMOVAL 670
INSTALLATION 671
DISASSEMBLY 672
ASSEMBLY 673
MAIN CONTROL VALVE 674
REMOVAL 674
INSTALLATION 676
DISASSEMBLY 677
ASSEMBLY 679
DUMP CYLINDER 681
REMOVAL 681
INSTALLATION 682
LIFT CYLINDER 683
REMOVAL 683
INSTALLATION 684
HYDRAULIC CYLINDER 685
DISASSEMBLY 685
ASSEMBLY 688
WORK EQUIPMENT 691
REMOVAL 691
INSTALLATION 694
COUNTERWEIGHT 696
REMOVAL 696
INSTALLATION 696
FUEL TANK 697
REMOVAL 697
INSTALLATION 698
CAB 699
REMOVAL 699
INSTALLATION 700
MAIN MONITOR 701
REMOVAL 701
INSTALLATION 702
MAINTENANCE MONITOR 703
REMOVAL 703
INSTALLATION 703
AIR CONDITIONER UNIT 704
REMOVAL 704
INSTALLATION 709
AIR CONDITIONER CONDENSER 710
REMOVAL 710
INSTALLATION 711
DRY RECEIVER 712
REMOVAL 712
INSTALLATION 712
AIR CONDITIONER COMPRESSOR 713
REMOVAL 713
INSTALLATION 714
40 MAINTENANCE STANDARD 715
ENGINE MOUNT, TRANSMISSION MOUNT 716
TORQUE CONVERTER 717
TRANSMISSION 718
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
BRAKE 744
PARKING BRAKE 746
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 OTHERS 764
ELECTRIC CIRCUIT DIAGRAM (1/4) 765
ELECTRIC CIRCUIT DIAGRAM (2/4) 766
ELECTRIC CIRCUIT DIAGRAM (3/4) 767
ELECTRIC CIRCUIT DIAGRAM (4/4) 768

DESCRIPTION:

Komatsu WA450-3 Wheel Loader Shop Manual SEBM015501 – PDF DOWNLOAD 

SERIAL NUMBERS WA450-3 53001 andup

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

S.V 26/12/24