Komatsu Wheel Loader WA400-5L service & repair manual

Description Komatsu Wheel Loader WA400-5L service & repair manual

Komatsu Wheel Loader WA400-5L pdf workshop service repair manual + operation & maintenance manual

Serial number A40001 and up

MANUAL CONTENT:
GENERAL
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
GENERAL ASSEMBLY DRAWING

STRUCTURE AND FUNCTION
COOLING SYSTEM
SPECIFICATIONS
ENGINE MOUNT, TRANSMISSION MOUNT
POWER TRAIN
POWER TRAIN SYSTEM DIAGRAM
WITHOUT TORQUE CONVERTER LOCKUP CLUTCH
WITH TORQUE CONVERTER LOCK-UP CLUTCH
DRIVE SHAFT (PROPELLER SHAFT)
TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER
WITHOUT LOCK-UP CLUTCH
PATH OF POWER TRANSMISSION
POWER FLOW
OIL FLOW
WITH LOCK-UP CLUTCH
PATH OF POWER TRANSMISSION
LOCK-UP CLUTCH DISENGAGED
LOCK-UP CLUTCH ENGAGED
OIL FLOW
TRANSMISSION
F and R CLUTCHES: WITHOUT LOCK-UP CLUTCH
F and R CLUTCHES: WITH LOCK-UP CLUTCH
1ST and 4TH CLUTCH
2ND and 3RD CLUTCH
CLUTCH OPERATION
CLUTCH ENGAGED
CLUTCH DISENGAGED
FORWARD 1ST
OPERATION
FORWARD 2ND
OPERATION
FORWARD 3RD
OPERATION
FORWARD 4TH
OPERATION
REVERSE 1ST
OPERATION
TRANSMISSION CONTROL VALVE
WITHOUT LOCK-UP CLUTCH
WITH LOCK-UP CLUTCH
ELECTRONIC CONTROL MODULATION VALVE (ECMV)
ECMV FOR SPEED CLUTCH
ECMV AND PROPORTIONAL SOLENOID
ECMV AND FILL SWITCH
ECMV ACTUATION
ECMV FOR LOCK-UP CLUTCH
OPERATION WHEN TRAVELING IN TORQUE CONVERTER DRIVE
WHEN TRAVELING IN DIRECT DRIVE (CHANGING FROM TORQUE CONVERTER DRIVE DIRECT DRIVE)
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
FLOW VALVE
AXLE
FRONT AXLE
REAR AXLE
DIFFERENTIAL
FRONT DIFFERENTIAL
REAR DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL OPERATION
FINAL DRIVE
AXLE MOUNTING, CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN, ORBIT ROLL
STEERING VALVE
OVERLOAD RELIEF VALVE
STEERING RELIEF VALVE
STEERING RELIEF VALVE OPERATION
DEMAND VALVE OPERATION
FLOW AMP
STEERING VALVE OPERATION
NEUTRAL
TURNING RIGHT
TURNING LEFT
ORBIT-ROLL VALVE
CONNECTION BETWEEN THE HAND PUMP AND SLEEVE
STOP VALVE
EMERGENCY STEERING PUMP
EMERGENCY STEERING MOTOR
STEERING CYLINDER
JOYSTICK STEERING
JOYSTICK PPC VALVE
STEERING SWITCH VALVE
BRAKE PIPING
BRAKE VALVE
BRAKE VALVE - LEFT
BRAKE VALVE - RIGHT
CHARGE VALVE
PPC RELIEF VALVE
ACCUMULATOR - BRAKE
SPECIFICATIONS
BRAKE
FRONT
REAR
PARKING BRAKE CONTROL
PARKING BRAKE
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE VALVE
HYDRAULIC PIPING
WORK EQUIPMENT CONTROL LEVER
FOR PPC VALVE
HYDRAULIC TANK
BREATHER
HYDRAULIC PUMPS
STEERING PUMP, SWITCH PUMP
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND
PILOT CONTROL PUMPS
E.C.S.S
WORK EQUIPMENT CONTROL VALVE
2-SPOOL VALVE
3-SPOOL VALVE
RELIEF VALVE
SAFETY-SUCTION VALVE
SUCTION VALVE
CUT-OFF VALVE
WORK EQUIPMENT CONTROL VALVE OPERATION
NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS
RAISED POSITION FOR THE LIFT ARM SPOOL
LOWER POSITION OF THE LIFT ARM SPOOL
FLOAT POSITION OF THE LIFT ARM SPOOL
DUMP POSITION FOR THE BUCKET SPOOL
TILT POSITION FOR THE BUCKET SPOOL
WORK EQUIPMENT PPC VALVE
ATTACHMENT PPC VALVE
COOLING FAN MOTOR
HYDRAULIC MOTOR
SUCTION VALVE
OPERATION OF REVOLUTION DIRECTION CHANGEOVER VALVE
COOLING FAN MOTOR DRIVE PUMP
SERVO VALVE
SAFETY VALVE
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER, LIFT ARM KICK-OUT
BUCKET POSITIONER
LIFT ARM KICK-OUT
PROXIMITY SWITCH OPERATION
WHEN LIFT ARM IS RAISED
WHEN BUCKET IS TILTED
WORK EQUIPMENT CYLINDER
LIFT ARM CYLINDER
BUCKET CYLINDER
CAB
AIR CONDITIONER
AIR CONDITIONER PIPING
MACHINE MONITORING SYSTEM
INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR
STARTING AND LIGHTING FUNCTIONS
LOAD METER
SENSING FUNCTIONS
POWER SUPPLY AND NETWORK
AUTOMATIC PREHEATING FUNCTION
MACHINE MONITOR
STANDARD SPECIFICATIONS
LOAD METER SPECIFICATION
TABLE OF MONITOR INDICATION ITEMS
SETTING THE MACHINE MONITOR
SERVICE MODE FUNCTIONS
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM
ITEMS RELATED TO MAINTENANCE MONITOR
REAL-TIME MONITORING FUNCTION
REAL-TIME MONITORING ITEMS
MACHINE SETTING
SETTING NECESSARY FOR OPTION MOUNTING
OPTIONAL DEVICE SETTING FOR MACHINE MONITOR
TRANSMISSION CONTROL SYSTEM
SYSTEM DIAGRAM
CONTROL FUNCTION
ELECTRIC CIRCUIT DIAGRAM (STANDARD)
TRANSMISSION CONTROLLER
WORK EQUIPMENT CONTROL SYSTEM
ELECTRIC CIRCUIT DIAGRAM
JOYSTICK OPTION ONLY
WORK EQUIPMENT CONTROLLER
JOYSTICK OPTION
ELECTRIC TRANSMISSION CONTROL
COMBINATION SWITCH
KICK DOWN, HOLD SWITCH
ENGINE START CIRCUIT
ENGINE STOP CIRCUIT
PREHEATING CIRCUIT
AUTOMATIC PREHEATING SYSTEM
ENGINE POWER MODE SELECTOR CIRCUIT
PARKING BRAKE CIRCUIT
SENSORS
ENGINE SPEED SENSOR
ENGINE OIL PRESSURE SENSOR
ENGINE OIL LEVEL SENSOR
TEMPERATURE SENSOR
COOLANT (FOR MONITOR), TORQUE CONVERTER OIL, HYDRAULIC OIL,TRANSMISSION OIL, BRAKE OIL
COOLANT TEMPERATURE SENSOR - PREHEATING
TRANSMISSION CUT-OFF PRESSURE SENSOR
COOLANT LEVEL SENSOR
FUEL LEVEL SENSOR
BOOM ANGLE SENSOR FOR LOAD METER
AIR CLEANER CLOGGING SENSOR
LOAD METER PRESSURE SENSOR
BATTERY FLUID LEVEL SENSOR
RELAY

TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
SPECIAL TOOLS
ENGINE COMPONENTS
MEASURING EXHAUST SMOKE
MEASURING EXHAUST TEMPERATURE
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING CRANCASE PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING BOOST PRESSURE
MEASURING FUEL PRESSURE
ADJUSTING ENGINE SPEED SENSOR
BLEEDING AIR FROM FUEL SYSTEM
MEASURING ENGINE SPEED
ADJUSTING ACCELERATOR PEDAL
ADJUSTING THE POWER MODE
ADJUSTING THE NORMAL MODE
ADJUSTING TRANSMISSION SPEED SENSOR
POWER TRAIN OIL PRESSURE
FLUSHING
TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT
TRANSMISSION VALVE FAILS
MOVING MACHINE
STEERING CONTROL
STEERING OIL PRESSURE
TESTING HYDRAULIC FAN
BRAKE SYSTEM
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
ACCUMULATOR CHARGE PRESSURE
PPC OIL PRESSURE
WORK EQUIPMENT HYDRAULIC PRESSURE
BUCKET POSITIONER
LIFT ARM KICK-OUT
PROXIMITY SWITCH ACTUATION
ADJUSTING MACHINE MONITOR
LOAD METER
BLEEDING AIR
RELEASING REMAINING PRESSURE
IN HYDRAULIC CIRCUIT
E.C.S.S. DAMPER CIRCUIT
PM-CLINIC INSPECTION TABLE

DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN PERFORMING SERVICE OPERATIONS
SPECIAL TOOL LIST
SKETCH OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
STRIPPING INSULATION
WIRE INSPECTION
CONTACT TERMINAL REMOVAL (HD30 TYPE)
CRIMPING CONTACT TERMINAL (HD30 TYPE)
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
CONTACT TERMINAL REMOVAL (DT TYPE)
CRIMPING CONTACT TERMINAL (DT TYPE)
INSERTION OF CONTACT TERMINAL (DT TYPE)
ENGINE
ALTERNATOR
CYLINDER HEAD
DAMPER
ENGINE OIL COOLER
ENGINE FRONT SEAL
ENGINE REAR SEAL
FUEL INJECTION PUMP FOR LEFT BANK
FUEL INJECTION PUMP FOR RIGHT BANK
NOZZLE HOLDER
STARTING MOTOR
TURBOCHARGER
WATER PUMP
REMOVAL
INSTALLATION
RADIATOR FAN MOTOR
REMOVAL
INSTALLATION
AFTERCOOLER
REMOVAL
INSTALLATION
FAN AND FAN MOTOR
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
PARKING BRAKE DISC PLATE
REMOVAL
INSTALLATION
TORQUE CONVERTER AND TRANSMISSION
REMOVAL
INSTALLATION
BLEEDING THE HYDRAULIC BRAKE CIRCUIT

OTHERS
POWER TRAIN OIL CIRCUIT DIAGRAM
WITHOUT TORQUE CONVERTER LOCKUP CLUTCH
WITH TORQUE CONVERTER LOCKUP CLUTCH
BRAKE OIL CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT SCHEMATIC
ELECTRICAL SCHEMATIC
STANDARD
FLOOR HARNESS - CAB
FLOOR HARNESS - TRANSMISSION CONTROLLER
FLOOR HARNESS - TRANSMISSION HARNESS
FLOOR HARNESS - REAR HARNESS
FLOOR HARNESS - RELAY UNITS
WITH JOYSTICK STEERING
FLOOR HARNESS - CAB
FLOOR HARNESS - TRANSMISSION CONTROLLER
FLOOR HARNESS - JOYSTICK HARNESS
FLOOR HARNESS - TRANSMISSION HARNESS
FLOOR HARNESS - REAR HARNESS
FLOOR HARNESS - RELAY UNITS
ENGINE HARNESS
REAR HARNESS
FRONT FRAME HARNESS
CAB HARNESS
MONITOR PANEL CONTROLLER
A/C RELAY HARNESS
TRANSMISSION HARNESS
JOYSTICK CONTROLLER HARNESS
KOMTRAX HARNESS

Engine SAA6D114E-2 workshop service repair manual