Komatsu WA450-1 Wheel Loader Shop Manual SEBM001700 PDF  

Description

Komatsu WA450-1 Wheel Loader Shop Manual SEBM001700 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu WA450-1 Wheel Loader Shop Manual SEBM001700 – PDF DOWNLOAD 

Language : English
Pages : 780
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA450-1 Wheel Loader Shop Manual SEBM001700 – PDF DOWNLOAD 

MACHINE MODEL  SERIAL No.
WA450-1                   20001 and up

COVER 1
CONTENTS 2
10 STRUCTURE AND FUNCTION 20
GENERAL 21
RADIATOR 23
TORQUE CONVERTER OIL COOLER 24
DAMPER 25
TORQUE CONVERTER AND TRANSMISSION PIPING 26
HYDRAULIC CIRCUIT FOR POWER TRAIN 27
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 28
TORQUE CONVERTER AND PTO 29
TRANSMISSION 32
TRANSMISSION CONTROL VALVE 37
TORQUE CONVERTER OIL FILTER 56
TRANSMISSION PILOT FILTER 57
TRANSFER 58
DRIVE SHAFT 59
AXLE MOUNT 60
AXLE AND DIFFERENTIAL 62
FINAL DRIVE 66
TIRE AND WHEEL 67
STEERING PIPING 68
HYDRAULIC CIRCUIT FOR STEERING 69
STEERING VALVE 71
ORBIT-ROLL VALVE 85
STOP VALVE 89
STEERING CYLINDER 90
STEERING COLUMN AND ORBIT-ROLL 91
CENTER HINGE PIN 92
BRAKE AND AIR PIPING 93
BRAKE AND AIR CIRCUIT SYSTEM 95
AIR TANK 96
SAFETY VALVE 97
BRAKE VALVE 98
AIR GOVERNOR 102
TWO-WAY VALVE 104
BRAKE CHAMBER 105
SLACK ADJUSTER 107
BRAKE 110
PARKING BRAKE 112
PARKING BRAKE SOLENOID VALVE 114
SPRING CYLINDER 115
BRAKE CALIPER 116
HYDRAULIC PIPING 117
HYDRAULIC CIRCUIT DIAGRAM 119
HYDRAULIC TANK 120
PPC VALVE 123
MAIN CONTROL VALVE 128
ACCUMULATOR 141
HYDRAULIC CYLINDER 142
BUCKET LINKAGE 144
BUCKET POSITIONER AND BOOM KICK-OUT 146
WORK EQUIPMENT LEVER LINKAGE 148
ELECTRICAL WIRING DIAGRAM 149
ELECTRICAL WIRING DIAGRAM CIRCUIT 150
ENGINE STARTING CIRCUIT 152
ENGINE STOP CIRCUIT 153
PREHEATING CIRCUIT 154
COMBINATION SWITCH 157
ELECTRICAL TRANSMISSION CONTROL 158
ELECTRICAL PARKING BRAKE CONTROL 169
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) 178
SENSORS 182
PROXIMITY SWITCH 188
20 TESTING AND ADJUSTING 192
STANDARD VALUE TABLE FOR ENGINE 193
STANDARD VALUE TABLE FOR CHASSIS 195
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 198
TOOL LIST FOR TESTING AND ADJUSTING 200
ADJUSTING VALVE CLEARANCE 202
MEASURING COMPRESSION PRESSURE 203
TESTING AND ADJUSTING FUEL INJECTION TIMING 204
MEASURING BLOW-BY PRESSURE 206
TESTING AND ADJUSTING FAN BELT TENSION 207
MEASURING EXHAUST GAS COLOR 208
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE 209
MEASURING ENGINE STALL SPEED 211
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION 213
MEASURING SHIFT LEVER 215
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL 216
TIRE AND WHEEL 218
MEASURING STEERING WHEEL PLAY 219
MEASURING OPERATING FORCE OF STEERING WHEEL 220
OPERATING TIME OF STEERING WHEEL 221
STEERING OIL PRESSURE 222
MEASURING BRAKE PEDAL 224
MEASURING AIR 225
BRAKE PERFORMANCE 228
CHECKING BRAKE OIL PRESSURE 229
MEASURING WEAR OF BRAKE DISC 230
AIR BLEEDING FROM BRAKE LINE 232
PARKING BRAKE PERFORMANCE 233
CHECKING AND ADJUSTING PARKING BRAKE 234
MEASURING DUMP AND LIFT CONTROL LEVERS 236
ADJUSTING DUMP AND LIFT CONTROL LEVERS 237
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT 239
MEASURING WORK EQUIPMENT 242
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT 243
ADJUSTING BUCKET POSITIONER 244
ADJUSTING BOOM KICK-OUT 245
ADJUSTING MACHINE MONITOR 246
TROUBLESHOOTING 247
ELECTRICAL CIRCUIT SYSTEM DIAGRAM 248
ELECTRICAL WIRING DIAGRAM 253
CONNECTOR TERMINAL NUMBERS 254
PRECAUTION WHEN HANDLING CONNECTOR 259
CHECKS BEFORE TROUBLESHOOTING 261
JUDGEMENT ON POWER TRAIN 262
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART 264
METHOD OF READING TROUBLESHOOTING TABLE 266
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM 268
POSITION OF CONNECTORS FOR TROUBLESHOOTING 269
E-1 ENGINE DOES NOT START 275
E-2 ENGINE DOES NOT STOP 279
E-3 ENGINE STOPS WHEN TRAVELING 279
E-4 PARKING BRAKE DOES NOT WORK 280
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING 281
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 283
E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL 283
E-8 TRANSMISSION DOES NOT WORK NORMALLY 284
E-9 KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1-F4 SWITCHES CORRECTLY) 304
E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION) 307
E-11 KICK-DOWN OPERATION IS NOT CANCELED 308
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2 310
E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED 310
E-14 PREHEAT DISPLAY STAYS ON 312
E-15 PREHEATING DOES NOT STOP 312
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM 313
POSITION OF CONNECTORS FOR TROUBLESHOOTING 315
M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS 321
a) NONE OF MONITOR PANEL LIGHTS UP 321
b) EXCEPT FOR SPEEDOMETER MODULE, NONE OF MONITOR PANEL LIGHTS UP 321
c) NONE OF CAUTION ITEMS LIGHT UP 321
d) SOME OTHER PARTS DO NOT LIGHT UP 321
M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT 322
M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES (LEVELS OF CHECK ITEMS ARE CORRECT) 323
a) (ENGINE OIL LEVEL) FLASHES 323
b) (RADIATOR WATER LEVEL) FLASHES 324
c) (BRAKE OIL LEVEL) FLASHES 324
M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY 326
a) (PREHEAT) LIGHT UP 326
b) (TRANSMISSION CUT-OFF) LIGHTS UP 326
c) (PARKING BRAKE) LIGHTS UP 327
d) (WORKING LAMP) LIGHTS UP 327
M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES 329
a) ENGINE OIL PRESSURE SYSTEM 329
b) ALTERNATOR SYSTEM 329
M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CAUTION ITEM FLASHES 330
a) ENGINE OIL PRESSURE SYSTEM 330
b) ALTERNATOR SYSTEM 330
M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES (FLASHING ITEMS ARE SPECIFIED VALUE) 332
a) (CHARGE LEVEL) FLASHES 332
b) (FUEL LEVEL) FLASHES 332
c) (BRAKE LINE FAILURE ) FLASHES 332
d) (ENGINE OIL PRESSURE) FLASHES 332
e) (RADIATOR WATER LEVEL) FLASHES 332
f) (AIR PRESSURE) FLASHES 333
g) (ENGINE WATER TEMPERATURE) FLASHES 333
h) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES 333
M-8 SPEED SENSOR DISPLAY STAYS AT’0′ 335
M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY 336
a) IF HIGH BEAM DOES NOT LIGHT UP 336
b) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF 336
c) IF HI BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSITION 337
M-10 TURN SIGNAL LAMP DOES NOT FLASH TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING 338
a) IF TURN SIGNAL LAMP DOES NOT FLASH 338
b) IF TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING 338
M-11 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND 339
M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS 340
M-13 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH 341
M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP 341
M-15 WHEN STARTING SWITCH IS TURNED TO ON POSITION, LAMPS DO NOT LIGHT UP FOR 4 SEC WHEN LAMP SWITCH IS ON, LAMPS DO NOT LIGHT UP 342
a) NONE OF PANEL LIGHTS UP 342
b) SOME OF PANEL LAMPS DO NOT LIGHT UP 342
M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP NIGHT LIGHTING STAYS ON 343
M-17 SERVICE METER DOES NOT WORK 344
M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED 344
M-19 ABNORMALITY IN AIR PRESSURE GAUGE 345
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA 345
b) IF INDICATOR REMAINS AT MAXIMUM LEVEL 345
M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 346
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA 346
b) IF INDICATOR REMAINS AT MINIMUM LEVEL 346
M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 347
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA 347
b) IF INDICATOR REMAINS AT MINIMUM LEVEL 347
M-22 ABNORMALITY IN FUEL GAUGE 348
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA 348
b) IF INDICATOR REMAINS AT FULL 348
TROUBLESHOOTING TABLE FOR HYDRAULIC AND MECHANICAL SYSTEM 349
TROUBLESHOOTING TABLE 350
TORQUE CONVERTER AND TRANSMISSION 350
T-1 MACHINE DOES NOT MOVE 350
T-2 MACHINE LACKS POWER OR SPEED (ALL SPEED RANGE) 352
T-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 353
T-4 TORQUE CONVERTER OIL TEMPERATURE TOO HIGH 354
STEERING SYSTEM 355
S-1 STEERING WHEEL DOES NOT TURN 355
S-2 STEERING WHEEL IS SLUGGISH 356
S-3 STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK 357
S-4 MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING 357
S-5 LEFT AND RIGHT TURNING RADII ARE DIFFERENT 357
S-6 WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT, CHASSIS IS SUBJECTED TO LARGE SHOCK 357
AIR AND BRAKE SYSTEM 358
A-1 AIR PRESSURE DOES NOT RISE AT ALL 358
A-2 AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE 359
A-3 BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE 360
A-4 BRAKE DOES NOT RELEASE, OR DRAGS 361
A-5 PARKING BRAKE DOES NOT RELEASE, OR DRAGS (APPLIES TO MACHINE EQUIPPED WITH AIR PARKING BRAKE) 362
WORK EQUIPMENT 363
H-1 LIFT ARM DOES NOT RISE 363
H-2 LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER 364
H-3 LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT 365
H-4 BUCKET CANNOT BE HELD DOWN WITH LIFT ARM CYLINDER 365
H-5 LIFT ARM HAS LARGE HYDRAULIC DRIFT 365
H-6 LIFT ARM MOVEMENT IS UNSTEADY DURING WORK 365
H-7 LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “RAISE” 365
H-8 BUCKET DOES NOT TILT BACK 366
H-9 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER 367
H-10 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK 368
H-11 BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER 368
H-12 BUCKET HAS LARGE HYDRAULIC DRIFT 368
H-13 BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD (MAIN CONTROL VALVE IN “HOLD”) 368
H-14 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “TILT BACK” 368
H-15 CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY 369
30 DISASSEMBLY AND ASSEMBLY 370
STARTING MOTOR 372
REMOVAL AND INSTALLATION 372
ALTERNATOR 373
REMOVAL AND INSTALLATION 373
INJECTION PUMP 374
REMOVAL AND INSTALLATION 374
WATER PUMP 375
REMOVAL AND INSTALLATION 375
NOZZLE HOLDER 376
REMOVAL 376
INSTALLATION 377
TURBOCHARGER 378
REMOVAL AND INSTALLATION 378
CYLINDER HEAD 379
REMOVAL 379
INSTALLATION 385
RADIATOR 392
REMOVAL 392
INSTALLATION 395
OIL COOLER 397
REMOVAL AND INSTALLATION 397
ENGINE 398
REMOVAL 398
INSTALLATION 404
FUEL TANK 410
REMOVAL 410
INSTALLATION 411
DAMPER 412
REMOVAL AND INSTALLATION 412
DISASSEMBLY 413
ASSEMBLY 415
TORQUE CONVERTER CHARGING PUMP 419
REMOVAL 419
INSTALLATION 420
TORQUE CONVERTER AND TRANSMISSION 421
REMOVAL 421
INSTALLATION 429
TORQUE CONVERTER 438
DISASSEMBLY 438
ASSEMBLY 442
TRANSMISSION 448
DISASSEMBLY 448
ASSEMBLY 461
TRANSFER 474
DISASSEMBLY 474
ASSEMBLY 477
TRANSMISSION CONTROL VALVE 482
REMOVAL 482
INSTALLATION 485
DISASSEMBLY AND ASSEMBLY 488
FRONT DIFFERENTIAL 492
REMOVAL 492
INSTALLATION 496
REAR DIFFERENTIAL 500
REMOVAL 500
INSTALLATION 504
DIFFERENTIAL 508
DISASSEMBLY 508
ASSEMBLY 511
FRONT AXLE 519
REMOVAL 519
INSTALLATION 522
REAR AXLE 525
REMOVAL 525
INSTALLATION 530
DRIVE SHAFT 535
DISASSEMBLY 535
ASSEMBLY 537
FINAL DRIVE 539
DISASSEMBLY 539
ASSEMBLY 543
STEERING VALVE 548
REMOVAL 548
INSTALLATION 550
DISASSEMBLY 553
ASSEMBLY 556
STEERING DEMAND VALVE 561
REMOVAL 561
INSTALLATION 563
DISASSEMBLY 566
ASSEMBLY 570
STEERING PUMP 574
REMOVAL 574
INSTALLATION 575
STEERING CYLINDER 576
REMOVAL 576
INSTALLATION 577
DISASSEMBLY 578
ASSEMBLY 580
CENTER HINGE PIN 583
REMOVAL 583
INSTALLATION 592
AIR GOVERNOR 603
DISASSEMBLY 603
ASSEMBLY 604
BRAKE VALVE 605
REMOVAL 605
INSTALLATION 606
DISASSEMBLY 607
ASSEMBLY 609
BRAKE CHAMBER 611
REMOVAL 611
INSTALLATION 613
DISASSEMBLY 615
ASSEMBLY 618
SLACK ADJUSTER 621
REMOVAL 621
INSTALLATION 623
DISASSEMBLY 625
ASSEMBLY 626
BRAKE 627
DISASSEMBLY 627
ASSEMBLY 633
SPRING CYLINDER 641
REMOVAL 641
INSTALLATION 642
DISASSEMBLY 643
ASSEMBLY 645
PARKING BRAKE 647
REMOVAL 647
INSTALLATION 649
PARKING BRAKE PAD 652
REMOVAL AND INSTALLATION 652
HYDRAULIC TANK 653
REMOVAL 653
INSTALLATION 657
HYDRAULIC PUMP 660
REMOVAL 660
INSTALLATION 661
HYDRAULIC FILTER 662
REMOVAL AND INSTALLATION 662
SWITCH, PPC PUMP 663
REMOVAL 663
INSTALLATION 664
PPC VALVE 665
REMOVAL 665
INSTALLATION 667
DISASSEMBLY AND ASSEMBLY 669
MAIN CONTROL VALVE 670
REMOVAL 670
INSTALLATION 673
DISASSEMBLY 675
ASSEMBLY 677
DUMP CYLINDER 679
REMOVAL 679
INSTALLATION 681
LIFT CYLINDER 683
REMOVAL 683
INSTALLATION 684
LIFT AND DUMP CYLINDERS 685
DISASSEMBLY 685
ASSEMBLY 687
WORK EQUIPMENT 690
REMOVAL 690
INSTALLATION 693
COUNTERWEIGHT 696
REMOVAL AND INSTALLATION 696
40 MAINTENANCE STANDARD 697
ENGINE MOUNT 698
TRANSMISSION MOUNT 699
TORQUE CONVERTER CHARGING PUMP 700
DAMPER 701
TORQUE CONVERTER AND PTO 702
TORQFLOW TRANSMISSION 704
1 TRANSMISSION 704
2 TRANSMISSION CONTROL VALVE 707
3 SOLENOID VALVE 715
TRANSFER 716
DIFFERENTIAL 718
FINAL DRIVE 720
DRIVE SHAFT 721
AXLE MOUNT 722
STEERING COLUMN AND ORBIT-ROLL 723
STEERING VALVE 724
STEERING PUMP 725
STEERING CYLINDER MOUNT 726
STEERING CYLINDER 727
CENTER HINGE PIN 728
BRAKE VALVE 730
BRAKE CHAMBER 732
SLACK ADJUSTER 733
BRAKE 734
PARKING BRAKE 736
SPRING CYLINDER 737
MAIN CONTROL VALVE 738
SWITCH AND PPC PUMP 740
HYDRAULIC PUMP 741
PPC VALVE 742
DUMP CYLINDER 744
LIFT CYLINDER 745
BUCKET LINKAGE 746
BUCKET POSITIONER AND BOOM KICK-OUT 748
BUCKET 749
90 OTHERS 750
CAB 751
AIR CONDITIONER 752
PIPING 752
AIR CONDITIONER UNIT 753
CONDENSER 754
COMPRESSOR 754
DRY RESERVOIR 755
AIR CONDITIONER WIRING DIAGRAM 756
AIR CONDITIONER ELECTRIC CIRCUIT 756
LOG LOADER 757
HYDRAULIC PIPING 757
HYDRAULIC CIRCUIT DIAGRAM 758
WORK EQUIPMENT LEVER LINKAGE 759
MAIN CONTROL VALVE 760
ARM CYLINDER 762
WORK EQUIPMENT 763
ELECTRICAL CIRCUIT DIAGRAM FOR BRAKE COOLING 764
DISASSEMBLY AND ASSEMBLY 765
CAB 766
REMOVAL 766
INSTALLATION 767
AIR CONDITIONER UNIT 768
REMOVAL 768
INSTALLATION 770
AIR CONDITIONER CONDENSER 772
REMOVAL AND INSTALLATION 772
DRY RESERVOIR 773
REMOVAL AND INSTALLATION 773
COMPRESSOR FOR AIR CONDITIONER 774
REMOVAL AND INSTALLATION 774
MAINTENANCE STANDARD 775
MAIN CONTROL VALVE FOR LOG LOADER 776
WORK EQUIPMENT FOR LOG LOADER 778
ARM CYLINDER FOR LOG LOADER 780

DESCRIPTION:

Komatsu WA450-1 Wheel Loader Shop Manual SEBM001700 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL No.
WA450-1                    20001 and up

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 28/12/24