Komatsu Wheel Loader WA450-6 WA480-6 service & repair manual

Description Komatsu Wheel Loader WA450-6 WA480-6 service & repair manual

Komatsu Wheel Loader WA450-6, WA480-6 pdf workshop service manual + operation & maintenance manual

Serial numbers:
WA450-6 66001 and up, A44001 and up
WA480-6 85001 and up, A38001 and up

Specifications, maintenance, technical data, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

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

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SUPPORT, COOLING AND FAN SYSTEM
Engine and Transmission Mounting
Cooling System
Specifications
Cooling Fan Pump
Control of Delivery
Servo Valve
Cooling Fan Motor  
Motor
Principle of Operation
Suction Valve
Operation of Reversible Valve
Safety Valve
POWER TRAIN SYSTEM
Drive Line Components
System Diagram
Drive Shaft System
Power Train Piping System
Torque Converter
Without Lockup Clutch
Power Transmitting Route
Oil Flow
With Lockup Clutch
Torque Flow
Lockup Clutch Disengaged
Lockup Clutch Engaged
Oil Flow
Transmission
Transmission with Lockup Clutch
F and R Clutch Packs
Without Lockup Clutch
With Lockup Clutch
1st and 4th Clutch
2nd and 3rd Clutch
Operation of Clutch Pack
When Clutch is Engaged
When Clutch is Disengaged
Transmission Torque Flow Route
Forward 1st Gear Speed
Forward 2nd Gear Speed
Forward 3rd Gear Speed
Forward 4th Gear Speed
Reverse 1st Gear Speed
Flow Control Valve
Valve Assembly
ECMV Operation Table
Electronic Control Modulation Valve (ECMV)
ECMV for Gear Speed Clutch
ECMV for Lockup Clutch
Main and Torque Converter Relief Valve System
DRIVE AXLE SYSTEM
Front and Rear Axles
Differential
When Traveling in a Straight Line
When Turning
Limited Slip Differential (if equipped)
Axle Carrier
Limited Slip Differential Operation
Generation of Braking Torque by Right / Left Side Gears
When Traveling in a Straight Line
When Machine is Turning
Final Drives
STEERING SYSTEM
Steering Piping Diagram
Steering Column
Steering Pump
Pump Unit
Servo Valve
LS Valve
PC Valve
Steering Valve
Operation of Flow Amplifier
Operation of Flow Control Spool
Operation of Steering Valve
Orbit-roll Valve
Connection of Hand Pump and Sleeve
Role of Centering Spring
Stop Valve
Steering Relief Valve (if equipped)
Steering Cylinder
Emergency Steering Motor (if equipped)
Emergency Steering Pump (if equipped)
SERVICE BRAKING SYSTEM
Brake Piping Diagram
Charge Valve
Main Relief Valve (R1)
PPC Relief Valve (R3)
Sequence Valve (H1)
Shuttle Valve (S1)
Brake Valve
Accumulator for Brake
Between Charge Valve and Brake Valve
Between Brake Valve and Brake Cylinder
Slack Adjuster
Brakes
Front Brake
Rear Brake
Parking Brake System
Brake Control
Parking Brake
Parking Brake Solenoid Valve
Emergency Parking Brake Release Valve
UNDERCARRIAGE AND FRAME
Axle Mounting and Center Hinge Pin
Tires
Tire Structure and Characteristic Comparisons
HYDRAULIC SYSTEM
Piping Diagram
Work Equipment Control Lever System
Hydraulic Tank
Tank Vent System
Specifications
Power Train Pump
Work Equipment Pump
Pump Unit
Pump Control Valve System
LS Valve
PC Valve
PC-EPC Valve
Work Equipment Control Valve
CLSS
Outline of CLSS
Basic Principle
Pressure Compensation Control
Function and Operation of Each Valve
Main Hydraulic Circuit Diagram of Valves
Pressure Compensation Valve
When a Heavy Load is Applied to the Lift Arm
During Compound Operation (Lift Arm Lower and Bucket Tilt)
Shuttle Valve in the Pressure Compensation Valve
Area Ratio of Pressure Compensation Valve
Supply of LS Pressure
LS Bypass Plug
ECSS Control Valve
Accumulator Pressure Relief Valve
Restriction on Lift Arm Raise Stroke
Accumulator Charge Valve
When Valve is in Neutral and (P) is Low
When Load Pressure (P) is High
PPC Valve
Work Equipment PPC Valve
Operation in Neutral
Operations During Fine Control
At Full Stroke
When Lift Arm is “Float”
When “Float” State of Lift Arm is Reset
Accumulator for PPC Circuit
Accumulator for ECSS
WORK EQUIPMENT
Work Equipment Linkage
Bucket
Bucket Positioner and Boom Kick-out
Bucket Positioner
Boom Kick-out
Proximity Switch
When Bucket is Tilted
When Lift Arm is Raised
Work Equipment Cylinders
Lift Cylinder
Bucket Cylinder
CAB ENVIRONMENT
Cab
Air Conditioner
Air Conditioner Piping Diagram
Refrigerant Circuit Diagram
Air Conditioner Unit
Blower and Intake Unit
Refrigerant Compressor
Condenser
Receiver
Air Conditioner Panel
ELECTRICAL SYSTEM
Machine Monitor System
Operator Mode
Service Mode
System Circuit Diagram
Monitor Display Functions
List of Items Displayed on Monitor
Monitor Operational Switches
Setting the Machine Monitor System
Character Display Function
Operator Mode Function
Service Mode Functions
Input and Output Signals
Transmission Controller System
Gear Shifting Control
Transmission Controller Protection
Engine Control Function
Economy Operation Pilot Lamp Function
Cooling Fan Control Function
Fan Reverse Rotation Function
Work Equipment Swash Plate Control
Transmission Cut-off
ECSS Function
Electric Emergency Steering (if equipped)
System Circuit Diagram
Transmission Controller
Input and Output Signals
Electronic Transmission Control
Combination Switch
Kickdown and Hold Switch
KOMTRAX Terminal System
KOMTRAX Terminal
Engine Starting Circuit
Engine Stopping Circuit
Preheating Circuit
Engine Power Mode Selector Circuit
Engine Output Derating
Automatic Warm-up

TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ENGINE COMPONENTS
Exhaust Smoke
Exhaust Temperature
Valve Clearance
Compression Pressure
Crankcase Pressure
Engine Oil Pressure
Boost Pressure
Fuel Pressure
Engine Speed Sensor
Bleeding Air from Fuel System
Engine Speed
Low Idling and High Idling
Measuring Torque Converter Stall Speed
Measuring Hydraulic Stall Speed
Measuring Torque Converter Stall and Hydraulic Stall (Full Stall) Speed
TRANSMISSION SPEED SENSOR
REFRIGERANT COMPRESSOR BELT

DISASSEMBLY AND ASSEMBLY
Removal and Installation of Assemblies
Disassembly and Assembly of Assemblies
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SCHEMATIC DRAWINGS 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)

OTHERS
ELECTRICAL SCHEMATICS
HYDRAULIC CIRCUIT DIAGRAM

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