Komatsu WA430-5 WA430-6 GALEO Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA430.zip
A full workshop service repair manual for the Komatsu WA430 Wheel Loader, complete with Electrical Wiring Diagrams, containing every technical detail needed to service, troubleshoot, fix, and rebuild the machine to a professional mechanic's standard.
The Komatsu WA430 Wheel Loader workshop service repair manual covers the following:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 13,857 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
Cover...1
00 Index and foreword...0
Index...3
Composition of shop manual...4
Table of contents...6
Foreword and general information...19
Safety notice...20
How to read the shop manual...25
Explanation of terms for maintenance standard...27
Handling of electric equipment and hydraulic component...29
Handling of connectors newly used for engines...38
How to read electric wire code...41
Precautions when carrying out operation...44
Method of disassembling and connecting push-pull type coupler...47
Standard tightening torque table...50
Conversion table...54
01 Specification...0
Specification and technical data...61
Specification dimension drawing...63
Specifications...64
Weight table...68
Table of fuel, coolant and lubricants...70
10 Structure, function and maintenance standard...0
Engine and cooling system...73
Engine mount and transmission mount...74
Cooling system...75
Cooling fan pump...76
Cooling fan motor...84
Power train...91
Power train...93
Power train system diagram...94
Drive shaft...96
Power train piping diagram...97
Torque converter...98
Transmission...106
Flow control valve...123
Transmission control valve...126
ECMV...130
Main relief valve and torque converter relief valve...136
Axle...138
Differential...140
Limited slip differential...146
Final drive...152
Steering system...159
Steering piping diagram...161
Steering column...162
Steering pump...163
Steering valve...175
Orbit-roll valve...190
Stop valve...194
Steering relief valve...195
Steering cylinder...196
Emergency steering motor...198
Emergency steering pump...199
Joystick steering lever linkage...200
Steering electric lever...201
Joystick EPC valve...202
Brake system...205
Brake piping diagram...206
Charge valve...207
Brake valve...214
Accumulator (for brake)...219
Brake...220
Parking brake control...225
Parking brake...226
Parking brake solenoid valve...228
Emergency parking brake release valve...230
Undercarriage and frame...233
Axle mount and center hinge pin...234
Tires...238
Hydraulic system, Part 1...241
Hydraulic piping diagram...242
Work equipment control lever linkage...245
Hydraulic tank...248
Power train pump...250
Work equipment pump...251
Work equipment control valve...262
CLSS...276
Each function and operation of each valve...280
Hydraulic system, Part 2...303
PPC valve...304
Stabilizer valve...312
Accumulator (for PPC circuit)...318
Accumulator (for ECSS)...319
Work equipment PPC cut-off solenoid valve...320
Work equipment...323
Work equipment linkage...324
Bucket...326
Bucket positioner and boom kick-out...327
Work equipment cylinder...333
Cab and its attachments...335
Cab...337
Air conditioner...338
Electrical system, Part 1...357
Machine monitor system...358
Machine monitor...362
Electrical system, Part 2...395
Electrical system (Transmission controller system)...396
Transmission controller...438
Electrical system (Work equipment controller system)...440
Work equipment controller...446
Electrical system, Part 3...449
Electric transmission control...450
Kickdown switch and hold switch...454
Load meter cancel switch and load meter subtotal switch...454
Multi-function knob...455
Joystick steering knob...456
KOMTRAX system...458
Engine starting circuit...460
Engine stopping circuit...462
Preheating circuit...463
Engine power mode selector circuit...464
Engine output derating function...465
Automatic warm-up function...465
Parking brake circuit...466
Sensor...468
20 Standard value table...0
Standard service value table...479
Standard value table for engine...480
Standard value table for chassis...481
30 Testing and adjusting...0
Testing and adjusting, Part 1...489
Tools for testing, adjusting, and troubleshooting...491
Testing engine speed...497
Testing exhaust gas color...499
Testing exhaust temperature...500
Adjusting valve clearance...502
Testing compression pressure...504
Testing blow-by pressure...508
Testing engine oil pressure...509
Testing intake air (boost) pressure...510
Handling fuel system equipment...511
Releasing residual pressure in fuel system...511
Testing fuel pressure...512
Testing fuel return and leak amount...518
Bleeding air from fuel circuit...520
Testing leakage in fuel system...521
Handling reduced cylinder mode operation...522
Handling no-injection cranking operation...522
Handling controller voltage circuit...523
Check of muffler and muffler stack for looseness and damage...524
Check of muffler function...524
Check of installed condition of cylinder head and manifolds...525
Check of engine piping for damage and looseness...525
Checking and replacing alternator belt...526
Checking and replacing auto- tensioner...528
Adjusting transmission speed sensor...530
Adjusting directional lever length...531
Adjusting gear shift lever length...531
Testing directional lever...532
Testing and adjusting power train oil pressure...533
Procedure for flushing torque converter and transmission hydraulic circuit...547
Method of moving machine when transmission valve is broken...548
Checking axle final drive for oil leakage...550
Checking drive shafts for looseness, play and damage...550
Testing and adjusting steering stop valve...551
Testing and adjusting steering wheel...553
Testing and adjusting steering oil pressure...555
Bleeding air from steering circuit...558
Testing and adjusting, Part 2...561
Testing hydraulic drive fan...563
Bleeding air from hydraulic drive fan circuit...565
Testing brake pedal...567
Testing and adjusting brake pedal linkage...568
Testing brake performance...569
Testing and adjusting accumulator charge pressure...570
Testing wheel brake oil pressure...571
Testing wear of wheel brake disc...573
Bleeding air from wheel brake circuit...574
Releasing residual pressure in brake accumulator circuit...575
Testing parking brake performance...576
Testing parking brake oil pressure...577
Testing wear of parking brake disc...579
Method of releasing parking brake manually...580
Testing and adjusting work equipment control lever...581
Testing and adjusting work equipment PPC oil pressure...582
Testing and adjusting work equipment oil pressure...585
Bleeding air from work equipment circuit...589
Releasing residual pressure in work equipment circuit...590
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator...591
Testing and adjusting bucket positioner...597
Testing and adjusting boom kickout...599
Checking proximity switch operation pilot lamp...600
Procedure for testing diodes...601
Preparation work for troubleshooting for electrical system...602
Starting KOMTRAX terminal operations...607
Indicator lamps of KOMTRAX terminal...612
Testing and adjusting, Part 3...617
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...618
Special functions of machine monitor (EMMS)...621
Pm-clinic inspection table...689
40 Troubleshooting...0
Failure code table and fuse locations...693
Failure code table...694
Fuse locations...705
General information on troubleshooting...709
Points to remember when troubleshooting...710
Sequence of events in troubleshooting...711
Testing before troubleshooting...712
Classification and procedures of troubleshooting...713
Information contained in troubleshooting table...716
Connection table for connector pin numbers...718
T- branch box and T- branch adapter table...754
Troubleshooting by failure code (Display of code), Part 1...759
Failure code [1500L0] (TORQFLOW transmission: Double meshing)...761
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...762
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...764
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...766
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...768
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...770
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...772
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...774
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...776
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...778
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...780
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...782
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...784
Failure code [2F00MA] (Parking brake: Malfunction)...786
Failure code [2G43ZG] (Accumulator: Low oil pressure)...788
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)...790
Troubleshooting by failure code (Display of code), Part 2...795
Failure code [AA1ANX] (Air cleaner: Clogging)...798
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...800
Failure code [AB00MA] (Alternator: Malfunction)...802
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...804
Failure code [B@BAZK] (Engine oil: Low level)...805
Failure code [B@BCNS] (Coolant: Overheating)...806
Failure code [B@BCZK] (Coolant: Low level)...808
Failure code [B@BEBF] (Water in fuel error)...810
Failure code [b@CENS] (Torque converter oil: Overheating)...812
Failure code [B@CENS] (Torque converter oil: Overheating)...814
Failure code [B@HANS] (Hydraulic oil: Overheating)...816
Failure code [CA111] (Abnormality in engine controller)...818
Failure code [CA115] (Engine Ne or Bkup speed sensor error)...819
Failure code [CA122] (Charge pressure sensor high error)...820
Failure code [CA123] (Charge pressure sensor low error)...822
Failure code [CA131] (Throttle sensor high error)...824
Failure code [CA132] (Throttle sensor low error)...826
Failure code [CA144] (Coolant sensor high error)...828
Failure code [CA145] (Coolant sensor low error)...830
Failure code [CA153] (Charge temperature sensor high error)...832
Failure code [CA154] (Charge temperature sensor low error)...834
Failure code [CA155] (Derating of speed by abnormally high charge temperature)...836
Failure code [CA187] (Sensor power supply 2 low error)...838
Failure code [CA221] (Atmospheric pressure sensor high error)...840
Failure code [CA222] (Atmospheric sensor low error)...842
Failure code [CA227] (Sensor power supply 2 high error)...844
Failure code [CA234] (Engine overspeed)...845
Failure code [CA238] (Ne speed sensor power supply error)...846
Troubleshooting by failure code (Display of code), Part 3...849
Failure code [CA271] (IMV/PCV1 Short circuit)...851
Failure code [CA272] (IMV/PCV1 Disconnection)...852
Failure code [CA281] High pressure pump error...854
Failure code [CA322] (Injector #1 open/short error)...856
Failure code [CA323] (Injector #5 open/short error)...858
Failure code [CA324] (Injector #3 open/short error)...860
Failure code [CA325] (Injector #6 open/short error)...862
Failure code [CA331] (Injector #2 open/short error)...864
Failure code [CA332] (Injector #4 open/short error)...866
Failure code [CA342] (Calibration code inconsistency)...868
Failure code [CA351] (Injectors drive circuit error)...870
Failure code [CA352] (Sensor power supply 1 low error)...872
Failure code [CA386] (Sensor power supply 1 high error)...874
Failure code [CA428] (Abnormally high level in water sensor)...875
Failure code [CA429] (Abnormally low level in water sensor)...876
Failure code [CA431] (Idle validation switch error)...878
Failure code [CA432] (Idle validation action error)...880
Failure code [CA435] (Engine oil pressure switch error)...882
Failure code [CA441] (Battery voltage low error)...883
Failure code [CA442] (Battery voltage high error)...886
Failure code [CA449] Common rail pressure high error 2...888
Failure code [CA451] (Common rail pressure sensor high error)...892