Komatsu Trash Compactor WF450-3 WF450T-3 Shop Manual VEBM080100 – PDF DOWNLOAD

Komatsu Trash Compactor WF450-3 WF450T-3 Shop Manual VEBM080100 – PDF DOWNLOAD

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Komatsu Trash Compactor WF450-3 WF450T-3 Shop Manual VEBM080100 – PDF DOWNLOAD

Language : English
Pages : 324
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File Type : PDF
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Komatsu Trash Compactor WF450-3 WF450T-3 Shop Manual VEBM080100 – PDF DOWNLOAD

SERIAL NUMBER
WF450-3 W078-54101 AND UP
WF450T-3 W077-54101 AND UP

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1 .Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

•  Always wear safety glasses when hitting parts with a hammer.
•  Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.PREPARATIONS FOR WORK:
1. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to
prevent the machine from moving.
2. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible,
use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting
work.
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

TABLE OF CONTENTS:

Komatsu Trash Compactor WF450-3 WF450T-3 Shop Manual VEBM080100 – PDF DOWNLOAD

WF450-3 / WF450T-3…………………………………………………………………………. 1
CONTENTS………………………………………………………………………………….. 3
00 SAFETY…………………………………………………………………………………. 5
Safety notice………………………………………………………………………….. 6
Preparations for work……………………………………………………………….. 7
Precautions during work……………………………………………………………… 8
Foreword………………………………………………………………………………. 10
How to read the shop manual……………………………………………………………… 11
Volumes……………………………………………………………………………. 11
Distribution and updating……………………………………………………………. 11
Filing method………………………………………………………………………. 11
Symbols……………………………………………………………………………. 12
Hoisting instructions…………………………………………………………………… 13
01 GENERAL………………………………………………………………………………… 15
Specifications…………………………………………………………………………. 16
WF450-3……………………………………………………………………………. 16
WF450T-3…………………………………………………………………………… 18
Weight table…………………………………………………………………………… 20
10 STRUCTURE AND FUNCTION…………………………………………………………………… 21
Power train……………………………………………………………………………. 24
Transmission…………………………………………………………………………… 26
Transmission solenoid valve……………………………………………………………… 31
Axle………………………………………………………………………………….. 33
Front axle…………………………………………………………………………. 33
Rear axle………………………………………………………………………….. 34
Differential…………………………………………………………………………… 35
Front differential………………………………………………………………….. 35
Rear differential…………………………………………………………………… 35
Final drive……………………………………………………………………………. 39
Axle mount, center hinge pin…………………………………………………………….. 41
Steering piping………………………………………………………………………… 42
Brake piping…………………………………………………………………………… 45
Brake…………………………………………………………………………………. 47
Parking brake………………………………………………………………………….. 49
Hydraulic component layout………………………………………………………………. 53
Work equipment lever linkage…………………………………………………………….. 54
WF450T-3…………………………………………………………………………… 54
WF450-3……………………………………………………………………………. 55
Hydraulic tank…………………………………………………………………………. 56
PPC valve……………………………………………………………………………… 57
WF450T-3…………………………………………………………………………… 57
WF450-3……………………………………………………………………………. 59
Operation of PPC valve [at neutral]…………………………………………………… 61
Function of PPC valve……………………………………………………………….. 62
Cut-off valve………………………………………………………………………….. 65
WF450-3……………………………………………………………………………. 65
Operation of cut-off valve…………………………………………………………… 66
Main control valve……………………………………………………………………… 67
WF450T-3…………………………………………………………………………… 67
WF450-3……………………………………………………………………………. 69
Main relief valve…………………………………………………………………… 71
Safety valve (with suction)………………………………………………………….. 73
Operation………………………………………………………………………. 73
Suction valve………………………………………………………………………. 74
Float selector valve and unload valve…………………………………………………. 75
WF450-3………………………………………………………………………… 75
Operation – WF450T-3………………………………………………………………… 76
Operation – WF450-3…………………………………………………………………. 80
Bucket positioner and boom kick-out………………………………………………………. 86
WF450-3……………………………………………………………………………. 86
Operation of proximity switch…………………………………………………….. 86
Operation of proximity switch…………………………………………………….. 89
Air conditioner………………………………………………………………………… 91
Air conditioner piping………………………………………………………………. 91
Machine monitor system………………………………………………………………….. 92
Main monitor…………………………………………………………………………… 93
Main monitor display function………………………………………………………… 94
Main monitor switch function…………………………………………………………. 95
Preheating output function…………………………………………………………… 96
Trouble data display mode (When optional controller are installed)……………………….. 97
Maintenance monitor…………………………………………………………………….. 98
Maintenance monitor display function………………………………………………….. 99
Engine starting circuit………………………………………………………………….102
Engine stop circuit……………………………………………………………………..103
Preheating circuit………………………………………………………………………104
(Automatic preheating system)…………………………………………………………104
Electric transmission control…………………………………………………………….106
WF450T-3……………………………………………………………………………106
WF450-3…………………………………………………………………………….107
Combination switch…………………………………………………………………..108
Kick-down switch………………………………………………………………………..111
WF450-3…………………………………………………………………………….111
Kick-down switch…………………………………………………………………111
Kick-down electric circuit diagram………………………………………………………..112
WF450-3…………………………………………………………………………….112
Normal operation…………………………………………………………………112
Kick-down switch operated (case I)…………………………………………………114
Canceling actuation of kick-down switch (Case I)…………………………………….116
Canceling actuation of kick-down switch (Case II)……………………………………118
Canceling actuation of kick-down switch (Case III)…………………………………..120
Standard value table for engine…………………………………………………………..124
Standard value table for chassis………………………………………………………….125
Standard value table for electrical parts………………………………………………….130
20 TESTING AND ADJUSTING…………………………………………………………………….121
Tools for testing, adjusting, and troubleshooting…………………………………………..135
Testing steering wheel…………………………………………………………………..137
Measuring play of steering wheel………………………………………………………137
Measuring operating force of steering wheel…………………………………………….138
Measuring operating time for steering wheel…………………………………………….139
Testing and adjusting steering control…………………………………………………….140
Measuring steering oil pressure…………………………………………………………..141
Testing and adjusting accumulator charge pressure…………………………………………..143
Testing drop in wheel brake oil pressure…………………………………………………..145
Measuring brake disc wear………………………………………………………………..147
Bleeding air from brake system……………………………………………………………149
Measuring parking brake performance……………………………………………………….150
Testing and adjusting work equipment hydraulic pressure……………………………………..151
WF450T-3……………………………………………………………………………151
Measuring PPC hydraulic pressure………………………………………………………….153
WF450T-3……………………………………………………………………………153
Measuring work equipment…………………………………………………………………155
WF450T-3……………………………………………………………………………155
Measuring hydraulic drift of work equipment………………………………………………..156
WF450T-3……………………………………………………………………………156
Adjusting main monitor (speedometer module)………………………………………………..157
20 TROUBLESHOOTING………………………………………………………………………….161
Outline………………………………………………………………………………..162
20 TROUBLESHOOTING OF HYDRAULICAL AND MECHANICAL SYSTEM (H MODE)…………………………………165
Work Equipment – WF450T-3………………………………………………………………..167
H-1 Blade does not rise………………………………………………………………167
H-2 Blade movement is slow or blade lacks lifting power………………………………….168
H-3 When blade is raised, it moves slowly at a certain height…………………………….169
H-4 Blade cannot be pushed with lift cylinder (blade floats)…………………………….169
H-5 Excessive hydraulic drift of blade…………………………………………………169
H-6 Blade and straight frame shake during operation……………………………………..170
H-7 Blade drops momentarily when control lever is operated from HOLD to RAISE………………170
H-8 Blade does not tilt………………………………………………………………171
H-9 Blade movement is slow or tilt lacks power………………………………………….172
H-10 Blade movement becomes slow during tilt operation………………………………….173
H-11 Blade cannot be pushed with tilt cylinder…………………………………………173
H-12 Excessive hydraulic drift of blade………………………………………………..173
H-13 Blade shakes during loading operation (main control valve at HOLD)……………………174
H-14 Blade tilts momentarily to left when control lever is operated from HOLD to RIGHT TILT….174
H-15 Blade control lever is heavy or does not move smoothly………………………………175
Steering system…………………………………………………………………………176
H-16 Steering does not turn…………………………………………………………..176
H-17 Steering wheel is heavy………………………………………………………….177
H-18 Steering wheel wobbles or there is excessive shock………………………………….178
H-19 Machine steers to one side when traveling………………………………………….179
H-20 Turning radius to left and right is different……………………………………..179
30 DISASSEMBLY AND ASSEMBLY………………………………………………………………….181
Special tool list……………………………………………………………………….183
Removal and installation of rear axle assembly……………………………………………..186
Removal and installation of hydraulic pump, PPC pump assembly………………………………..187
WF450-3…………………………………………………………………………….187
WF450T-3……………………………………………………………………………187
Disassembly and assembly of hydraulic cylinder assembly…………………………………….188
WF450-3…………………………………………………………………………….188
WF450T-3……………………………………………………………………………188
Main control valve assembly………………………………………………………………189
Removal…………………………………………………………………………….189
Installation………………………………………………………………………..190
Fuel tank………………………………………………………………………………191
Removal…………………………………………………………………………….191
Installation………………………………………………………………………..193
Radiator, oil cooler assembly…………………………………………………………….194
Removal…………………………………………………………………………….194
Installation………………………………………………………………………..196
Engine hood assembly…………………………………………………………………….197
Removal…………………………………………………………………………….197
Installation………………………………………………………………………..198
Lift cylinder assembly…………………………………………………………………..199
Removal…………………………………………………………………………….199
Installation………………………………………………………………………..200
Tilt cylinder assembly…………………………………………………………………..201
Removal…………………………………………………………………………….201
Installation………………………………………………………………………..202
Work equipment assembly………………………………………………………………….203
Removal…………………………………………………………………………….203
Installation………………………………………………………………………..206
Assembly……………………………………………………………………………212
Front axle assembly……………………………………………………………………..217
Removal (WF450-3)……………………………………………………………………217
Installation (WF450-3)……………………………………………………………….219
Removal (WF450T-3)…………………………………………………………………..220
Installation (WF450T-3)………………………………………………………………222
Removal and installation of rear axle assembly……………………………………………..223
Front differential assembly………………………………………………………………224
Removal…………………………………………………………………………….224
Installation………………………………………………………………………..225
Differential Assembly……………………………………………………………………226
Disassembly…………………………………………………………………………226
Assembly……………………………………………………………………………231
40 MAINTENANCE STANDARD……………………………………………………………………..243
Engine mount, transmission mount………………………………………………………….245
Torque converter………………………………………………………………………..246
Transmission……………………………………………………………………………248
(1/2)………………………………………………………………………………248
(2/2)………………………………………………………………………………250
Forward, 1st clutch………………………………………………………………….252
2nd, reverse clutch………………………………………………………………….253
3rd, 4th clutch……………………………………………………………………..254
Transmission control valve……………………………………………………………….255
Modulation valve assembly…………………………………………………………….255
Upper valve assembly…………………………………………………………………256
Lower valve assembly…………………………………………………………………258
Flow valve………………………………………………………………………….260
Accumulator valve……………………………………………………………………261
Drive shaft…………………………………………………………………………….262
Differential……………………………………………………………………………263
Limited slip differential………………………………………………………………..264
Final drive…………………………………………………………………………….265
Axle mount……………………………………………………………………………..266
Center hinge pin………………………………………………………………………..268
Steering column…………………………………………………………………………270
Steering valve………………………………………………………………………….271
Steering cylinder mount………………………………………………………………….272
Slack adjuster………………………………………………………………………….273
Brake valve…………………………………………………………………………….274
Left……………………………………………………………………………….274
Right………………………………………………………………………………275
Brake………………………………………………………………………………….276
Parking brake…………………………………………………………………………..277
Torque converter, transmission pump……………………………………………………….278
SAR(3) – 100………………………………………………………………………..278
Steering, switch pump……………………………………………………………………279
SAR(3)71 + 50……………………………………………………………………….279
Hydraulic, PPC pump……………………………………………………………………..280
WF450T-3 – SAR(3)80 + (1) 28………………………………………………………….280
WF450-3 – SAR(4)140 + (1) 28………………………………………………………….281
PPC valve………………………………………………………………………………282
WF450T-3……………………………………………………………………………282
WF450-3…………………………………………………………………………….283
Cut-off valve…………………………………………………………………………..284
WF450-3…………………………………………………………………………….284
Main control valve………………………………………………………………………286
WF450T-3……………………………………………………………………………286
WF450-3…………………………………………………………………………….288
Lift cylinder…………………………………………………………………………..290
WF450T-3……………………………………………………………………………290
Boom cylinder…………………………………………………………………………..291
WF450-3…………………………………………………………………………….291
Bucket cylinder…………………………………………………………………………292
WF450-3…………………………………………………………………………….292
Work equipment linkage…………………………………………………………………..294
WF450T-3……………………………………………………………………………294
WF450-3…………………………………………………………………………….296
Bucket positioner and boom kick-out……………………………………………………….298
WF450-3…………………………………………………………………………….298
90 OTHERS………………………………………………………………………………….299
Transmission hydraulic circuit diagram…………………………………………………….300
Brake hydraulic circuit diagram…………………………………………………………..302
Work equipment hydraulic circuit diagram (WF450T-3)…………………………………………305
Work equipment hydraulic circuit diagram (WF450-3)………………………………………….307
Electric circuit diagram [1/4)] (WF450T-3)…………………………………………………309
Electric circuit diagram [2/4)] (WF450T-3)…………………………………………………311
Electric circuit diagram [3/4)] (WF450T-3)…………………………………………………313
Electric circuit diagram [4/4)] (WF450T-3)…………………………………………………315
Electric circuit diagram [1/4)] (WF450-3)………………………………………………….317
Electric circuit diagram [2/4)] (WF450-3)………………………………………………….319
Electric circuit diagram [3/4)] (WF450-3)………………………………………………….321
Electric circuit diagram [4/4)] (WF450-3)………………………………………………….323

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