Komatsu Wheel Loader WA400-5H Shop Manual

WA400-5H PART I
CONTENTS
00 SAFETY / FOREWORD
SAFETY NOTICE
FOREWORD
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS
01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND COOLANT
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
COOLING SYSTEM
ENGINE MOUNT, TRANSMISSION MOUNT
POWER TRAIN
POWER TRAIN SYSTEM DIAGRAM
DRIVE SHAFT (PROPELLER SHAFT)
TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER
TRANSMISSION
TRANSMISSION CONTROL VALVE
AXLE
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNTING, CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN, ORBIT-ROLL
STEERING VALVE
ORBIT-ROLL VALVE
STOP VALVE
STEERING PUMP, SWITCH PUMP
EMERGENCY STEERING PUMP (OP)
EMERGENCY STEERING MOTOR (OP)
STEERING CYLINDER
JOYSTICK STEERING LEVER (OP)
STEERING LEVER (OP) (FOR JOYSTICK STEERING LEVER)
STEERING SWITCH VALVE (OP) (FOR JOYSTICK STEERING LEVER)
BRAKE PIPING
BRAKE VALVE
CHARGE VALVE
ACCUMULATOR (FOR BRAKE)
BRAKE
PARKING BRAKE CONTROL
PARKING BRAKE
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE VALVE
HYDRAULIC PIPING
WORK EQUIPMENT CONTROL LEVER
HYDRAULIC TANK
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS
PPC RELIEF VALVE
TRAVEL DAMPER VALVE (OP)
WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT PPC VALVE
EPC SOLENOID VALVE (OP)
SHUT OFF VALVE (OP)
ATTACHMENT PPC VALVE (OP)
COOLING FAN MOTOR
COOLING FAN MOTOR DRIVE PUMP
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER, LIFT ARM KICK-OUT
WORK EQUIPMENT CYLINDER
CAB
AIR CONDITIONER (OP)
MACHINE MONITORING SYSTEM
MACHINE MONITOR
TRANSMISSION CONTROL SYSTEM
TRANSMISSION CONTROLLER
WORK EQUIPMENT CONTROL SYSTEM (OP)
WORK EQUIPMENT CONTROLLER
ELECTRIC TRANSMISSION CONTROL
KICK DOWN, HOLD SWITCH
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
PREHEATING CIRCUIT
ENGINE POWER MODE SELECTOR CIRCUIT
PARKING BRAKE CIRCUIT
SENSORS
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
MEASURING ENGINE SPEED
MEASURING EXHAUST COLOR
MEASURING EXHAUST TEMPERATURE
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING ENGINE SPEED SENSOR
BLEEDING AIR FROM FUEL CIRCUIT
ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ACCELERATOR PEDAL
ADJUSTING TRANSMISSION SPEED SENSOR
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
DRAWING OF SPECIAL TOOL
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
TESTING AND ADJUSTING STEERING CONTROL
TESTING AND ADJUSTING STEERING OIL PRESSURE
TESTING HYDRAULIC FAN
MEASURING BRAKE OIL PRESSURE
TESTING WEAR OF WHEEL BRAKE DISC
BLEEDING AIR FROM BRAKE CIRCUIT
TESTING WEAR OF PARKING BRAKE DISC
MANUAL RELEASE METHOD FOR PARKING BRAKE
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
TESTING AND ADJUSTING BUCKET POSITIONER
TESTING AND ADJUSTING LIFT ARM KICK-OUT
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP
ADJUSTING MACHINE MONITOR
TESTING AND ADJUSTING LOAD METER
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT
20 TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM
SPECIAL FUNCTIONS OF MACHINE MONITOR
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR LAYOUT DRAWING
TRANSMISSION CONTROL SYSTEM DIAGRAM
20 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR LAYOUT DRAWING
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
20 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR LAYOUT DRAWING
MONITOR SYSTEM DIAGRAM
20 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
20 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR LAYOUT DRAWING
ELECTRICAL SYSTEM DIAGRAM
WA400-5H PART II
DISASSEMBLY AND ASSEMBLY
Method of using manual
Precautions when carrying out operation
Engine assembly
Cylinder head assembly
Radiator and fan motor assembly
Aftercooler assembly
Fuel injection pump
Nozzle holder assembly
Fan and fan motor assembly
Fuel tank assembly
Parking brake disc plate
Torque converter and transmission assembly
Transmission assembly
Transmission clutch pack assembly
Parking brake assembly
Special tool simplified drawings
Torque converter assembly (standard specification)
Torque converter assembly (lock-up specification)
Rear axle assembly
Front axle assembly
Axle housing assembly
Special tool simplified drawings
Differential assembly
Special tool illustrations
Center hinge pin
Cab assembly
Cab and floor frame assembly
Transmission, work equipment, and PPC pump assembly
Steering, switching, and fan pump assembly
Steering demand valve assembly
E.C.S.S. valve assembly
Work equipment valve assembly
Hydraulic cylinder assembly (steering, lift, and bucket cylinder assembly)
Hydraulic tank assembly
Work equipment assembly
Counter weight
Air conditioner unit assembly
Air conditioner compressor assembly
90 OTHERS
POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)
POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)
BRAKE OIL CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER)