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KOMATSU WA450-3LL LOG LOADER SHOP MANUAL SEBM009904 – PDF DOWNLOAD
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KOMATSU WA450-3LL LOG LOADER SHOP MANUAL SEBM009904 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA450-3LL LOG LOADER SHOP MANUAL SEBM009904 – PDF DOWNLOAD
Language : English
Pages : 789
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA450-3LL LOG LOADER SHOP MANUAL SEBM009904 – PDF DOWNLOAD
COVER................................................................................................................................................................. 1 CONTENTS.............................................................................................................................................................. 2 01 GENERAL............................................................................................................................................................ 28 GENERAL ASSEMBLY DRAWING.......................................................................................................................................... 29 SPECIFICATIONS.................................................................................................................................................... 31 WEIGHT TABLE...................................................................................................................................................... 34 LIST OF LUBRICANT AND WATER....................................................................................................................................... 36 10 STRUCTURE AND FUNCTION............................................................................................................................................. 38 POWER TRAIN....................................................................................................................................................... 39 POWER TRAIN SYSTEM ............................................................................................................................................... 40 TORQUE CONVERTER, TRANSMISSION PIPING............................................................................................................................. 42 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM............................................................................................................................. 43 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................ 44 TORQUE CONVERTER.................................................................................................................................................. 45 TORQUE CONVERTER OIL FILTER....................................................................................................................................... 48 TRANSMISSION...................................................................................................................................................... 49 TRANSMISSION CONTROL VALVE........................................................................................................................................ 59 TRANSMISSION SOLENOID VALVE....................................................................................................................................... 81 PILOT OIL FILTER.................................................................................................................................................. 82 DRIVE SHAFT....................................................................................................................................................... 83 AXLE.............................................................................................................................................................. 84 DIFFERENTIAL...................................................................................................................................................... 86 FINAL DRIVE....................................................................................................................................................... 90 AXLE MOUNT,CENTER HINGE PIN....................................................................................................................................... 91 STEERING PIPING................................................................................................................................................... 93 STEERING COLUMN................................................................................................................................................... 94 STEERING VALVE.................................................................................................................................................... 95 ORBIT-ROLL VALVE..................................................................................................................................................109 STOP VALVE........................................................................................................................................................113 EMERGENCY STEERING PUMP (OPTION)..................................................................................................................................114 DIVERTER VALVE (OPTION)..........................................................................................................................................115 BRAKE PIPING......................................................................................................................................................118 BRAKE CIRCUIT DIAGRAM.............................................................................................................................................119 BRAKE VALVE.......................................................................................................................................................121 CHARGE VALVE......................................................................................................................................................126 ACCUMULATOR (FOR BRAKE)...........................................................................................................................................130 SLACK ADJUSTER....................................................................................................................................................131 BRAKE COOLING PIPING..............................................................................................................................................134 BRAKE COOLING CIRCUIT DIAGRAM.....................................................................................................................................135 BRAKE.............................................................................................................................................................136 BRAKE COOLING.....................................................................................................................................................138 PARKING BRAKE CONTROL.............................................................................................................................................139 PARKING BRAKE.....................................................................................................................................................140 PARKING BRAKE SOLENOID VALVE......................................................................................................................................141 PARKING BRAKE VALVE...............................................................................................................................................142 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE....................................................................................................................143 HYDRAULIC PIPING..................................................................................................................................................144 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM...........................................................................................................................145 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................147 WORK EQUIPMENT LEVER LINKAGE......................................................................................................................................148 HYDRAULIC TANK....................................................................................................................................................149 PPC VALVE.........................................................................................................................................................151 PPC RELIEF VALVE..................................................................................................................................................156 ACCUMULATOR (FOR PPC VALVE).......................................................................................................................................157 CUT-OFF VALVE.....................................................................................................................................................158 MAIN CONTROL VALVE................................................................................................................................................161 WORK EQUIPMENT LINKAGE............................................................................................................................................175 LOG GRAPPLE.......................................................................................................................................................177 FORK POSITIONER AND LIFT ARM KICK-OUT.............................................................................................................................178 CAB (OPTION)......................................................................................................................................................184 AIR CONDITIONER (OPTION)..........................................................................................................................................185 ELECTRIC CIRCUIT DIAGRAM..........................................................................................................................................186 MACHINE MONITOR SYSTEM............................................................................................................................................188 MAIN MONITOR......................................................................................................................................................189 MAINTENANCE MONITOR...............................................................................................................................................194 E.C.S.S...........................................................................................................................................................196 SENSORS...........................................................................................................................................................200 ENGINE STARTING CIRCUIT...........................................................................................................................................205 ENGINE STOP CIRCUIT...............................................................................................................................................206 PREHEATING CIRCUIT................................................................................................................................................207 ELECTRIC TRANSMISSION CONTROL.....................................................................................................................................208 KICK-DOWN SWICTH..................................................................................................................................................211 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM................................................................................................................................212 TRANSMISSION CUT-OFF SWITCH.......................................................................................................................................217 TRANSMISSION CUT-OFF FUNCTION.....................................................................................................................................218 ELECTRIC PARKING BRAKE CONTROL....................................................................................................................................220 20 TESTING AND ADJUSTING..............................................................................................................................................232 STANDARD VALUE TABLE FOR ENGINE...................................................................................................................................233 STANDARD VALUE TABLE FOR CHASSIS..................................................................................................................................234 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.........................................................................................................................237 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...................................................................................................................240 MEASURING ENGINE SPEED............................................................................................................................................241 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)....................................................................................................................242 ADJUSTING VALVE CLEARANCE.........................................................................................................................................243 MEASURING EXHAUST COLOR...........................................................................................................................................244 MEASURING EXHAUST GAS TEMPERATURE.................................................................................................................................245 MEASURING BLOW-BY PRESSURE........................................................................................................................................246 MEASURING COMPRESSION PRESSURE....................................................................................................................................247 MEASURING ENGINE OIL PRESSURE.....................................................................................................................................248 TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................................................................................................249 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE......................................................................................................................251 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................................................253 MEASURING ACCELERATOR PEDAL.......................................................................................................................................254 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER..................................................................................................................256 MEASURING STALL SPEED.............................................................................................................................................257 MEASURING TORQUE CONVERTER,TRANSMISSION,PARKING BRAKE OIL PRESSURE................................................................................................259 METHOD OF OPERATING EMERGENCY MANUAL SPOOL........................................................................................................................261 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL........................................................................................................................263 TESTING AND ADJUSTING STEERING WHEEL..............................................................................................................................264 TESTING AND ADJUSTING STEERING CONTROL............................................................................................................................267 MEASURING STEERING OIL PRESSURE...................................................................................................................................268 MEASURING OPERATING FORCE,TRAVEL OF BRAKE PEDAL...................................................................................................................270 MEASURING BRAKE PERFORMANCE.......................................................................................................................................271 TESTING BRAKE OIL PRESSRUE........................................................................................................................................272 MEASURING BRAKE DISC WEAR.........................................................................................................................................273 BLEEDING AIR FROM BRAKE SYSTEM....................................................................................................................................274 BLEEDING AIR FROM BRAKE COOLING OIL LINE..........................................................................................................................275 MEASURING PARKING BRAKE PERFORMANCE...............................................................................................................................276 MANUAL RELEASE METHOD FOR PARKING BRAKE...........................................................................................................................277 TESTING WEAR OF PARKING BRAKE DISC................................................................................................................................278 MEASURING WORK EQUIPMENT CONTROL LEVER............................................................................................................................279 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE.......................................................................................................................281 MEASURING WORK EQUIPMENT..........................................................................................................................................285 TESTING AND ADJUSTING FORK PISITIONER.............................................................................................................................287 TESTING AND ADJUSTING LIFT ARM KICK-OUT...........................................................................................................................288 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE).......................................................................................................................290 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR.....................................................................................................................291 TROUBLESHOOTING...................................................................................................................................................292 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................................................293 SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................................................294 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.....................................................................................................................295 HANDLING CONNECTORS...........................................................................................................................................302 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................303 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................................304 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................................................312 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................................................318 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....................................................................................................................325 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).............................................................................................326 S-2 ENGINE DOES NOT START.................................................................................................................................327 (1) ENGINE DOES NOT TURN..............................................................................................................................327 (2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)............................................................................328 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..........................................................................329 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................................................330 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................................331 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).............................................................................................................332 S-6 ENGINE LACKS OUTPUT (NO POWER)........................................................................................................................333 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)..........................................................................................................334 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).................................................................................................335 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................................336 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................................337 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN................................................................................338 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...................................................................................................339 S-13 OIL LEVEL RISES......................................................................................................................................340 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................................................................341 S-15 ABNORMAL NOISE IS MADE...............................................................................................................................342 S-16 VIBRATION IS EXCESSIVE...............................................................................................................................343 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...............................................................................................................344 TROUBLE DATA DISPLAY (OPTION).............................................................................................................................346 M-1 MAIN MONITOR DOES NOT WORK............................................................................................................................347 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP........................................................348 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY............................................................................................................349 M-4 ABNORMALITY IN SHIFT INDICATOR........................................................................................................................350 (a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F....................................................................................................350 (b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R....................................................................................................350 (c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F..............................................350 (d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R..............................................351 (e) DOES NOT DISPLAY 1ST,4TH..........................................................................................................................351 (f) DOES NOT DISPLAY 3RD,4TH..........................................................................................................................352 (g) DOES NOT DISPLAY 2ND,3RD..........................................................................................................................352 (h) DOES NOT DISPLAY 1ST,2ND..........................................................................................................................353 M-5 HIGH BEAM DOES NOT LIGHT UP...........................................................................................................................354 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP.................................................................................................................355 (a) L.H. TURN SIGNAL DOES NOT LIGHT UP................................................................................................................355 (b) R.H. TURN SIGNAL DOES NOT LIGHT UP................................................................................................................355 M-7 ABMORMALITY IN PARKING DISPLAY........................................................................................................................356 (a) PARKING LAMP DOES NOT LIGHT UP....................................................................................................................356 (b) PARKING LAMP STAYS LIGHTED UP.....................................................................................................................356 M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS)................................................................................................................357 (a) DOES NOT CARRY OUT PREHEATING.....................................................................................................................357 (b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE........................................................................................................358 (c) PREHEATING STAYS ON...............................................................................................................................358 (d) PREHEATING TIME BECOMES SHORTER,OR THERE IS VARIATION.............................................................................................359 M-9 NIGHT LIGHTING DOES NOT LIGHT UP......................................................................................................................360 M-10 ABNORMALITY IN FRONT WORKING LAMP (OPTION)...........................................................................................................361 (a) NEITHER MONITOR DISPLAY NOT FRONT WORKING LAMP LIGHT UP...........................................................................................361 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP......................................................................................361 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP..............................................................................................361 M-11 ABNORMALITY IN REAR WORKING LAMP.....................................................................................................................362 (a) NEITHER MONITOR DISPLAY NOT REAR WORKING LAMP LIGHT UP............................................................................................362 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP......................................................................................362 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP..............................................................................................362 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF..................................................................................................................364 (a) WHEN MONITOR SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN..........................................................364 (b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON............................................................................................364 (c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED....................................................................................365 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING........................................................................................................366 (a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N,AND CAUTION LAMP FLASHES.........................366 (b) WHEN PARKING BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N....366 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED................................367 (a) ACTUATED CONTINUOUSLY.............................................................................................................................367 (b) NOT ACTUATED......................................................................................................................................367 M-15 ABNORMALITY IN BUZZER................................................................................................................................368 (a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON(DURING SELF-CHECK)........................................................................368 (b) BUZZER ALWAYS SOUNDS..............................................................................................................................368 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY................................................................................................369 M-17 ABNORMALITY IN FAILURE DISPLAY MODE..................................................................................................................370 (a) DOES NOT ENTER FAILURE DISPLAY MODE...............................................................................................................370 (b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE......................................................................370 M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY (OPTION)............................................................................................371 (a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP...............................................................................................371 (b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP................................................................................................371 M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY (OPTION).........................................................................................372 (a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP............................................................................................372 (b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP.............................................................................................372 M-20 ABNORMALITY IN ECSS STSTEM (OPTION)..................................................................................................................373 (a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED....................................................................................................373 (b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK.........................................................................................373 M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK ) (OPTION)..........................................................................374 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)........................................................................................................375 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS ,MAINTENANCE MONITOR DOES NOT WORK..................376 (a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS....................................................................................376 (b) SOME LAMPS DO NOT LIGHT UP........................................................................................................................377 K-2 WHEN STARTING SWITCH IS TURNED ON ,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT........................................................377 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWICTH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTINANCE MONITOR DO NOT GO OUT..............378 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH.................................................................................379 (a) ENGINE OIL LEVEL DISPLAY FLASHES..................................................................................................................379 (b) ENGINE WATER LEVEL DISPLAY FLASHES................................................................................................................380 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARED), CAUTION ITIMS FLASH................................................................................381 (a) ENGINE OIL PRESSURE DISPLAY FLASHES...............................................................................................................381 (b) BATTERY CHARGE LEVEL DISPLAY FLASHES..............................................................................................................382 (c) BRAKE OIL PRESSURE DISPLAY FLASHES................................................................................................................383 (d) BRAKE OIL TEMPERATURE DISPLAY FLASHES.............................................................................................................384 (e) AIR CLEANER DISPLAY FLASHES.......................................................................................................................385 K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND............................................................................................386 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS....................................................................................387 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP..............................................................388 (a) CHECK LAMP........................................................................................................................................388 (b) CAUTION LAMP......................................................................................................................................388 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP,CAUTION LAMP) LIGHTS UP...........................................389 (a) CHECK LAMP........................................................................................................................................389 (b) CAUTION LAMP......................................................................................................................................389 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)..............................390 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP...............................................................391 K-12 SERVICE METER DOES NOT WORK..........................................................................................................................392 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED.................................................................................................392 K-14 ABNORMALITY IN GAUGE ITEMS...........................................................................................................................393 (a) ABNORMALITY IN FUEL GAUGE.........................................................................................................................393 (b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.....................................................................................................394 (c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.............................................................................................395 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).................................................................................................................396 E-1 ENGINE DOES NOT START.................................................................................................................................397 (a) STARTING MOTOR DOES NOT TURN......................................................................................................................397 (b) STARTING MOTOR TURNS..............................................................................................................................401 E-2 ENGINE DOES NOT STOP..................................................................................................................................403 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING................................................................................................................403 E-4 PARKING BRAKE DOES NOT WORK...........................................................................................................................404 (a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (PARKING)......................................................................404 (b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS.............................................................................................404 E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING....................................................................................................405 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...........................................................................................407 E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.................................................................................407 E-8 TRANSMISSION DOES NOT WORK NORMALLY...................................................................................................................408 (a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)..................................................................................410 (b) PROBLEM IN H-L CIRCUIT............................................................................................................................410 (c) PROBLEM IN SPEED CIRCUIT..........................................................................................................................411 (d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH).......................................................................................................411 (e) CONTACT IN H-L CIRCUIT............................................................................................................................412 (f) CONTACT IN SPEED CIRCUIT..........................................................................................................................414 (g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)......................................................................................................416 (h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)....................................................................................................417 (i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)....................................................................................................419 (j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD,PARKING BRAKE IS NORMAL)...............................................421 (k) CONTACT IN FORWARD CIRCUIT........................................................................................................................423 (l) CONTACT IN REVERSE CIRCUIT........................................................................................................................425 (m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE.................................................................................................427 E-9 KICK-DOWN SWITCH DOES NOT WORK........................................................................................................................428 E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON.....................................................................................................430 E-11 KICK-DOWN OPERATION CANNOT BE CANCELED...............................................................................................................430 (a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R................................................................................430 (b) NOT CANCELED EVEN WHEN SPEED LEVEL IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH)..............................................................431 E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND........................................................................................433 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE).................................................................................434 POWER TRAIN...............................................................................................................................................435 T-1 MACHINE DOES NOT START............................................................................................................................435 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES..............................................................................437 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR............................................................................................439 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.........................................................................................440 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..........................................................................................................441 STEERING SYSTEM...........................................................................................................................................442 T-6 STEERING DOES NOT TURN............................................................................................................................442 T-7 STEERING WHEEL IS HEAVY...........................................................................................................................443 T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK................................................................................................444 T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING.........................................................................................................444 T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT....................................................................................................444 BRAKE SYSTEM..............................................................................................................................................445 T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.....................................................................................................445 T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG...........................................................................................................446 T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS.....................................................................................................447 WORK EQUIPMENT............................................................................................................................................448 T-14 LIFT ARM DOES NOT RISE...........................................................................................................................448 T-15 LIFT ARM MOVEMENT IS SLOW OR LIFT ARM LACKS LIFTING POWER........................................................................................449 T-16 WHEN LIFT ARM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.....................................................................................450 T-17 FORK CANNOT BE PUSHED WITH LIFT ARM CYLINDER (FORK FLOATS).......................................................................................450 T-18 EXCESSIVE HYDRAULIC DRIFT OF LIFT ARM............................................................................................................450 T-19 LIFT ARM SHAKES DURING OPERATION.................................................................................................................450 T-20 LIFT ARM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLE TO RAISE.....................................................................451 T-21 FORK DOES NOT TILT BACK..........................................................................................................................452 T-22 FORK MOVEMENT IS SLOW OR TILT-BACK LACKS POWER...................................................................................................453 T-23 FORK MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION............................................................................................454 T-24 FORK CANNOT BE PUSHED WITH FORK CYLINDER.........................................................................................................454 T-25 EXCESSIVE HYDRAULIC DRIFT OF FORK................................................................................................................454 T-26 FORK SHAKES DURING LOADING OPERATION.............................................................................................................455 T-27 FORK DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT..........................................................................455 T-28 LIFT ARM, FORK CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY..................................................................................456 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) (OPTION).......................................................................457 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM..........................................................................................................458 D-1 ECSS DOES NOT WORK....................................................................................................................................459 (a) ERROR CODE [d0] IS DISPLAYED......................................................................................................................460 (b) ERROR CODE [d1] IS DISPLAYED......................................................................................................................460 (c) ERROR CODE [d2] IS DISPLAYED......................................................................................................................461 (d) ERROR CODE [d3] IS DISPLAYED......................................................................................................................461 (e) ERROR CODE [d4] IS DISPLAYED......................................................................................................................462 (f) NO ABNORMALITY DISPLAY IS GIVEN...................................................................................................................462 D-2 ECSS CANNOT BE CANCELED...............................................................................................................................466 D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 km/h) (DEVEATES AROUND 5 km/h) ...................................................................467 D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST.......................................................................................................467 D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH.......................................................................................................468 D-6 CONTROLLER LED CODE IS NOT DISPLAYED..................................................................................................................469 D-7 ECSS IS ABNORMAL BUT MAIL NONITOR DOES NOT GIVE ABNORMALITY DISPLAY...................................................................................469 30 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................470 METHOD OF USING MANUAL............................................................................................................................................472 PRECAUTIONS WHEN CARRYING OUT OPERATION...........................................................................................................................473 SPECIAL TOOL LIST.................................................................................................................................................475 STARTING MOTOR....................................................................................................................................................477 REMOVAL.......................................................................................................................................................477 INSTALLATION..................................................................................................................................................477 ALTERNATOR........................................................................................................................................................478 REMOVAL ......................................................................................................................................................478 INSTALLATION..................................................................................................................................................478 ENGINE OIL COOLER.................................................................................................................................................479 REMOVAL ......................................................................................................................................................479 INSTALLATION..................................................................................................................................................479 FUEL INJECTION PUMP...............................................................................................................................................480 REMOVAL ......................................................................................................................................................480 INSTALLATION..................................................................................................................................................481 WATER PUMP........................................................................................................................................................482 REMOVAL ......................................................................................................................................................482 INSTALLATION..................................................................................................................................................482 TURBOCHARGER......................................................................................................................................................483 REMOVAL ......................................................................................................................................................483 INSTALLATION..................................................................................................................................................483 NOZZLE HOLDER.....................................................................................................................................................484 REMOVAL ......................................................................................................................................................484 INSTALLATION..................................................................................................................................................484 THERMOSTAT........................................................................................................................................................485 REMOVAL ......................................................................................................................................................485 INSTALLATION..................................................................................................................................................485 CYLINDER HEAD.....................................................................................................................................................486 REMOVAL ......................................................................................................................................................486 INSTALLATION..................................................................................................................................................490 RADIATOR..........................................................................................................................................................492 REMOVAL ......................................................................................................................................................492 INSTALLATION..................................................................................................................................................494 ENGINE............................................................................................................................................................495 REMOVAL ......................................................................................................................................................495 INSTALLATION..................................................................................................................................................500 TORQUE CONVERTER, TRANSMISSION....................................................................................................................................502 REMOVAL ......................................................................................................................................................502 INSTALLATION..................................................................................................................................................509 TORQUE CONVERTER..................................................................................................................................................511 DISASSEMBLY...................................................................................................................................................511 ASSEMBLY......................................................................................................................................................513 TRANSMISSION......................................................................................................................................................516 DISASSEMBLY...................................................................................................................................................516 ASSEMBLY......................................................................................................................................................521 TRANSMISSION CLUTCH PACK..........................................................................................................................................527 DISASSEMBLY...................................................................................................................................................527 ASSEMBLY......................................................................................................................................................536 PARKING BRAKE.....................................................................................................................................................548 DISASSEMBLY...................................................................................................................................................548 ASSEMBLY......................................................................................................................................................550 TRANSMISSION CONTROL VALVE........................................................................................................................................553 REMOVAL ......................................................................................................................................................553 INSTALLATION..................................................................................................................................................555 DISASSEMBLY...................................................................................................................................................556 ASSEMBLY......................................................................................................................................................561 TRANSMISSION ACCUMULATOR VALVE....................................................................................................................................567 DISASSEMBLY...................................................................................................................................................567 ASSEMBLY......................................................................................................................................................568 DRIVE SHAFT.......................................................................................................................................................569 DISASSEMBLY...................................................................................................................................................569 ASSEMBLY......................................................................................................................................................571 FRONT AXLE........................................................................................................................................................573 REMOVAL ......................................................................................................................................................573 INSTALLATION..................................................................................................................................................575 REAR AXLE ........................................................................................................................................................576 REMOVAL ......................................................................................................................................................576 INSTALLATION..................................................................................................................................................579 FRONT DIFFERENTIAL................................................................................................................................................582 REMOVAL ......................................................................................................................................................582 INSTALLATION..................................................................................................................................................585 REAR DIFFERENTIAL.................................................................................................................................................587 REMOVAL ......................................................................................................................................................587 INSTALLATION..................................................................................................................................................590 DIFFERENTIAL......................................................................................................................................................592 DISASSEMBLY...................................................................................................................................................592 ASSEMBLY......................................................................................................................................................595 FINAL DRIVE.......................................................................................................................................................603 DISASSEMBLY...................................................................................................................................................603 ASSEMBLY......................................................................................................................................................606 CENTER HINGE PIN..................................................................................................................................................610 REMOVAL ......................................................................................................................................................610 INSTALLATION..................................................................................................................................................619 STEERING VALVE (ORBIT-ROLL).......................................................................................................................................625 REMOVAL ......................................................................................................................................................625 INSTALLATION..................................................................................................................................................626 STEERING VALVE....................................................................................................................................................627 DISASSEMBLY...................................................................................................................................................627 ASSEMBLY......................................................................................................................................................630 REMOVAL ......................................................................................................................................................635 INSTALLATION..................................................................................................................................................636 STEERING DEMAND VALVE.............................................................................................................................................637 DISASSEMBLY...................................................................................................................................................637 ASSEMBLY......................................................................................................................................................641 STEERING, SWITCH PUMP.............................................................................................................................................645 REMOVAL ......................................................................................................................................................645 INSTALLATION..................................................................................................................................................648 STEERING CYLINDER.................................................................................................................................................649 REMOVAL ......................................................................................................................................................649 INSTALLATION..................................................................................................................................................650 BRAKE VALVE.......................................................................................................................................................651 REMOVAL ......................................................................................................................................................651 INSTALLATION..................................................................................................................................................652 RIGHT BRAKE VALVE (TANDEM)........................................................................................................................................653 DISASSEMBLY...................................................................................................................................................653 ASSEMBLY......................................................................................................................................................654 LEFT BRAKE VALVE (SINGLE).........................................................................................................................................655 DISASSEMBLY...................................................................................................................................................655 ASSEMBLY......................................................................................................................................................656 SLACK ADJUSTER....................................................................................................................................................657 REMOVAL ......................................................................................................................................................657 INSTALLATION..................................................................................................................................................658 DISASSEMBLY...................................................................................................................................................659 ASSEMBLY......................................................................................................................................................660 BRAKE.............................................................................................................................................................661 DISASSEMBLY...................................................................................................................................................661 ASSEMBLY......................................................................................................................................................667 PARKING BRAKE DISC................................................................................................................................................676 REMOVAL ......................................................................................................................................................676 INSTALLATION..................................................................................................................................................678 HYDRAULIC TANK....................................................................................................................................................679 REMOVAL ......................................................................................................................................................679 INSTALLATION..................................................................................................................................................681 BRAKE COOLING OIL TANK............................................................................................................................................682 REMOVAL ......................................................................................................................................................682 INSTALLATION..................................................................................................................................................683 BRAKE OIL COOLER..................................................................................................................................................684 REMOVAL ......................................................................................................................................................684 INSTALLATION..................................................................................................................................................686 WORK EQUIPMENT, PPC, BRAKE COOLING PUMP...........................................................................................................................687 REMOVAL ......................................................................................................................................................687 INSTALLATION..................................................................................................................................................690 PPC VALVE.........................................................................................................................................................691 REMOVAL ......................................................................................................................................................691 INSTALLATION..................................................................................................................................................692 DISASSEMBLY...................................................................................................................................................693 ASSEMBLY......................................................................................................................................................694 MAIN CONTROL VALVE................................................................................................................................................695 REMOVAL ......................................................................................................................................................695 INSTALLATION..................................................................................................................................................697 DISASSEMBLY...................................................................................................................................................698 ASSEMBLY......................................................................................................................................................700 FORK CYLINDER.....................................................................................................................................................702 REMOVAL ......................................................................................................................................................702 INSTALLATION..................................................................................................................................................703 LIFT ARM CYLINDER.................................................................................................................................................704 REMOVAL ......................................................................................................................................................704 INSTALLATION..................................................................................................................................................705 GRAPPLE ARM CYLINDER..............................................................................................................................................706 REMOVAL ......................................................................................................................................................706 INSTALLATION..................................................................................................................................................707 HYDRAULIC CYLINDER................................................................................................................................................708 DISASSEMBLY...................................................................................................................................................708 ASSEMBLY......................................................................................................................................................711 WORK EQUIPMENT....................................................................................................................................................714 REMOVAL ......................................................................................................................................................714 INSTALLATION..................................................................................................................................................718 COUNTERWEIGHT.....................................................................................................................................................720 REMOVAL ......................................................................................................................................................720 INSTALLATION..................................................................................................................................................720 FUEL TANK.........................................................................................................................................................721 REMOVAL ......................................................................................................................................................721 INSTALLATION..................................................................................................................................................722 CAB (OPTION)......................................................................................................................................................723 REMOVAL ......................................................................................................................................................723 INSTALLATION..................................................................................................................................................724 MAIN CMONITOR.....................................................................................................................................................725 REMOVAL ......................................................................................................................................................725 INSTALLATION..................................................................................................................................................726 MAINTENANCE MONITOR...............................................................................................................................................727 REMOVAL ......................................................................................................................................................727 INSTALLATION..................................................................................................................................................727 40 MAINTENANCE STANDARD...............................................................................................................................................728 ENGINE MOUNT, TRANSMISSION MOUNT .................................................................................................................................729 TORQUE CONVERTER..................................................................................................................................................731 TRANSMISSION......................................................................................................................................................732 TRANSMISSION CONTROL VALVE........................................................................................................................................740 DRIVE SHAFT ......................................................................................................................................................747 DIFFERENTIAL......................................................................................................................................................748 FINAL DRIVE.......................................................................................................................................................750 AXLE MOUNT........................................................................................................................................................751 STEERING COLUMN...................................................................................................................................................753 STEERING VALVE....................................................................................................................................................754 STEERING CYLINDER MOUNT...........................................................................................................................................755 SLACK ADJUSTER....................................................................................................................................................756 BRAKE VALVE.......................................................................................................................................................757 BRAKE.............................................................................................................................................................760 PARKING BRAKE.....................................................................................................................................................762 TORQUE CONVERTER, TRANSMISSION PUMP...............................................................................................................................763 STEERING, SWITCH PUMP.............................................................................................................................................764 HYDRAULIC, PPC PUMP...............................................................................................................................................765 PPC VALVE.........................................................................................................................................................766 CUT-OFF VALVE.....................................................................................................................................................767 MAIN CONTROL VALVE................................................................................................................................................768 LIFT ARM CYLINDER.................................................................................................................................................770 FORK CYLINDER.....................................................................................................................................................771 CENTER HINGE PIN..................................................................................................................................................772 WORK EQUIPMENT LINKAGE............................................................................................................................................776 FORK POSITIONER AND LIFT ARM KICK-OUT.............................................................................................................................779 90 OTHERS.............................................................................................................................................................780 BRAKE PIPING......................................................................................................................................................781 HYDRAULIC PIPING..................................................................................................................................................782 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................783 ELECTRIC CIRCUIT DIAGRAM (1/4)....................................................................................................................................784 ELECTRIC CIRCUIT DIAGRAM (2/4)....................................................................................................................................785 ELECTRIC CIRCUIT DIAGRAM (3/4)....................................................................................................................................786 ELECTRIC CIRCUIT DIAGRAM (4/4)....................................................................................................................................787 ELECTRIC CIRCUIT DIAGRAM E.C.S.S..................................................................................................................................788 CONNECTOR PIN ARRANGEMENT DIAGRAM (1/3)...........................................................................................................................789
DESCRIPTION:
KOMATSU WA450-3LL LOG LOADER SHOP MANUAL SEBM009904 – PDF DOWNLOAD
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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together
S.S 12/12/24
