Komatsu Trash Compaktor WF550-3 WF550T-3 Shop Manual VEBM090100 – PDF DOWNLOAD

Komatsu Trash Compaktor WF550-3 WF550T-3 Shop Manual VEBM090100 – PDF DOWNLOAD

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Komatsu Trash Compaktor WF550-3 WF550T-3 Shop Manual VEBM090100 – PDF DOWNLOAD 

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Pages : 394
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Komatsu Trash Compaktor WF550-3 WF550T-3 Shop Manual VEBM090100 – PDF DOWNLOAD 

SERIAL NUMBER
WF550-3 W089-50001 AND UP
WF550T-3 W090-50001 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 Compaktor WF550-3 WF550T-3 Shop Manual VEBM090100 – PDF DOWNLOAD 

WF550-3 / WF550T-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
WF550-3………………………………………………………………………… 16
WF550T-3……………………………………………………………………….. 18
Weight table……………………………………………………………………….. 20
WF550-3………………………………………………………………………… 20
WF550T-3……………………………………………………………………….. 21
10 STRUCTURE AND FUNCTION……………………………………………………………….. 23
General……………………………………………………………………………. 26
Outline………………………………………………………………………… 27
Drive unit cooling fan………………………………………………………………. 29
Hydraulic motor…………………………………………………………………. 29
Cooling fan controller…………………………………………………………… 30
Forward/reverse timer……………………………………………………………. 31
Electromagnetic selector valve……………………………………………………. 32
Transmission……………………………………………………………………….. 34
Main relief, torque converter relief valve…………………………………………….. 40
Outline………………………………………………………………………… 41
Operation of main relief valve……………………………………………………. 42
Operation of torque converter relief valve…………………………………………. 43
Axle………………………………………………………………………………. 46
Front………………………………………………………………………….. 46
Rear…………………………………………………………………………… 47
Differential……………………………………………………………………….. 48
Front differential………………………………………………………………. 48
Rear differential……………………………………………………………….. 48
Outline…………………………………………………………………….. 49
Limited slip differential……………………………………………………………. 50
Operation of limited slip differential…………………………………………….. 51
Mechanism for generation of brake torque of left and right side gears (6)……………… 51
When travelling in straight line………………………………………………….. 52
When turning……………………………………………………………………. 53
Final drive………………………………………………………………………… 54
Outline………………………………………………………………………… 54
Operation………………………………………………………………………. 54
Axle mount, center hinge pin…………………………………………………………. 55
Outline………………………………………………………………………… 55
Steering piping…………………………………………………………………….. 56
Brake piping……………………………………………………………………….. 59
Brake……………………………………………………………………………… 62
Function……………………………………………………………………….. 63
Operation………………………………………………………………………. 63
Parking brake emergency release solenoid valve…………………………………………. 65
Function……………………………………………………………………….. 65
Operation………………………………………………………………………. 65
Hydraulic piping……………………………………………………………………. 66
Work equipment lever linkage…………………………………………………………. 67
WF550T-3……………………………………………………………………….. 67
WF550-3………………………………………………………………………… 68
Hydraulic tank……………………………………………………………………… 69
PPC valve………………………………………………………………………….. 71
WF550T-3……………………………………………………………………….. 71
WF550-3………………………………………………………………………… 73
Operation of PPC valve…………………………………………………………… 75
Function of PPC valve……………………………………………………………. 76
Operation…………………………………………………………………… 76
Cut-off valve………………………………………………………………………. 79
WF550-3………………………………………………………………………… 79
Function……………………………………………………………………. 79
Operation of cut-off valve……………………………………………………….. 80
Operation…………………………………………………………………… 80
Main control valve………………………………………………………………….. 81
WF550T-3……………………………………………………………………….. 81
WF550-3………………………………………………………………………… 83
Main relief valve…………………………………………………………………… 85
WF550T-3……………………………………………………………………….. 85
Function……………………………………………………………………. 85
Operation…………………………………………………………………… 85
WF550-3………………………………………………………………………… 86
Function……………………………………………………………………. 86
Operation…………………………………………………………………… 86
Safety valve (with suction)………………………………………………………. 87
Function……………………………………………………………………. 87
Operation as safety valve…………………………………………………….. 87
Operation as suction valve……………………………………………………. 88
Suction valve………………………………………………………………………. 89
Function……………………………………………………………………….. 89
Operation………………………………………………………………………. 89
Float selector valve and unload valve…………………………………………………. 90
WF550-3………………………………………………………………………… 90
Function……………………………………………………………………. 90
Operation…………………………………………………………………… 90
Operation (WF550T-3)………………………………………………………………… 92
Lift spool hold position…………………………………………………………. 92
Lift spool at raise position……………………………………………………… 94
Lift spool at lower position……………………………………………………… 96
Lift spool at float position……………………………………………………… 98
Operation (WF550-3)………………………………………………………………….100
Boom and bucket spool hold position………………………………………………..100
Boom spool at raise position………………………………………………………102
Boom spool at lower position………………………………………………………104
Boom spool at float position………………………………………………………106
Bucket spool at dump position……………………………………………………..108
Bucket spool at tilt position……………………………………………………..110
Bucket positioner and boom kick-out (WF550-3)…………………………………………..112
Operation of proximity switch for boom kick-out……………………………………..112
Action of proximity switch for boom-kickout…………………………………………114
Operation of proximity switch for bucket positioner…………………………………115
Action of proximity switch for bucket positioner…………………………………….116
Air conditioner……………………………………………………………………..117
Air conditioner piping……………………………………………………………117
Machine monitor system……………………………………………………………….118
Outline…………………………………………………………………………119
Main monitor………………………………………………………………………..120
Outline…………………………………………………………………………121
Main monitor display function……………………………………………………..122
Main monitor switch function………………………………………………………123
Preheating output function………………………………………………………..123
Trouble data display mode (when optional controller are installed)…………………….124
Maintenance monitor………………………………………………………………….126
Outline…………………………………………………………………………127
Maintenance monitor display function……………………………………………….128
All-Range Electronic Control Automatic Transmission System……………………………129
Outline of system…………………………………………………………….129
System structure diagram………………………………………………………….130
Function…………………………………………………………………….131
Transmission controller power source……………………………………………….136
Input signals……………………………………………………………………137
Output signals…………………………………………………………………..140
LED display……………………………………………………………………..142
Transmission controller………………………………………………………………144
Connector signals………………………………………………………………..145
Electric transmission control…………………………………………………………148
Function………………………………………………………………………..149
Combination switch……………………………………………………………….150
Outline……………………………………………………………………..150
General locations, function……………………………………………………150
Operation……………………………………………………………………151
20 TESTING AND ADJUSTING…………………………………………………………………155
Standard value table for engine……………………………………………………….157
Standard value table for chassis………………………………………………………158
WF550-3…………………………………………………………………………158
WF550T-3………………………………………………………………………..163
Standard value table for electrical parts………………………………………………167
Table of required tools………………………………………………………………179
Sketch of special tools………………………………………………………………180
Tool N………………………………………………………………………….180
Measuring blow-by pressure……………………………………………………………181
Measuring engine oil pressure…………………………………………………………182
Adjusting speed sensor……………………………………………………………….183
Engine speed sensor………………………………………………………………183
Transmission output shaft speed sensor……………………………………………..183
Adjusting of engine stop motor cable…………………………………………………..184
Torque converter and transmission oil pressure………………………………………….186
Steering oil pressure………………………………………………………………..190
Measuring……………………………………………………………………….190
Adjusting……………………………………………………………………….192
Measuring parking brake oil pressure…………………………………………………..193
Testing and adjusting PPC oil pressure…………………………………………………195
Measuring……………………………………………………………………….195
Adjusting……………………………………………………………………….197
Adjusting PPC valve linkage…………………………………………………………..198
Work equipment hydraulic pressure……………………………………………………..199
Adjusting……………………………………………………………………….200
Adjusting work equipment lever linkage…………………………………………………201
Adjusting main monitor (speedometer module)…………………………………………….202
20 TROUBLESHOOTING………………………………………………………………………205
Outline…………………………………………………………………………….206
Connector types and mounting locations…………………………………………………207
Connector arrangement diagram…………………………………………………………210
20 TROUBLESHOOTING FOR RADIATOR COOLING FAN SYSTEM (EC MODE)…………………………………215
Electric circuit diagram of cooling fan system………………………………………….216
EC-1 Fan does not rotate (selector switch position: AUTO)………………………………..218
EC-2……………………………………………………………………………….222
Fan does not rotate (selector switch position: MANUAL)……………………………….222
EC-3……………………………………………………………………………….226
Fan does not switch from forward to reverse rotation (selector switch position: AUTO)……226
EC-4……………………………………………………………………………….227
Fan does not switch from forward to reverse rotation (selector switch position: MANUAL)….227
EC-5……………………………………………………………………………….228
Fan does not switch from reverse to forward rotation (selector switch position: AUTO)……228
EC-6……………………………………………………………………………….229
Fan does not switch from reverse to forward rotation (selector switch position: MANUAL)….229
EC-7……………………………………………………………………………….230
When direction of fan is switched, it immediately switches……………………………230
20 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)……………………………….233
H-1 Blade does not move………………………………………………………………234
H-2 Blade is slow or blade lacks power…………………………………………………235
H-3, H-4, H-5, H-6…………………………………………………………………..236
H-3 – When blade is raised, it moves slowly at a certain height……………………….236
H-4 – Blade cannot be pushed with lift cylinder (blade floats)………………………..236
H-5 – Excessive hydraulic drift of blade……………………………………………237
H-6 – Blade shakes during operation………………………………………………..237
30 DISASSEMBLY AND ASSEMBLY………………………………………………………………239
Special tool list……………………………………………………………………240
Sketches of special tools…………………………………………………………….245
Starting motor assembly………………………………………………………………248
Removal…………………………………………………………………………248
Installation…………………………………………………………………….248
Engine front seal……………………………………………………………………249
Removal…………………………………………………………………………249
Installation…………………………………………………………………….249
Radiator assembly……………………………………………………………………250
Removal…………………………………………………………………………250
Installation…………………………………………………………………….251
Engine assembly……………………………………………………………………..252
Removal…………………………………………………………………………252
Installation…………………………………………………………………….256
Front axle assembly………………………………………………………………….257
Removal…………………………………………………………………………257
Installation…………………………………………………………………….258
Front differential assembly…………………………………………………………..259
Removal…………………………………………………………………………259
Installation…………………………………………………………………….261
Rear axle assembly…………………………………………………………………..262
Removal…………………………………………………………………………262
Installation…………………………………………………………………….267
Rear differential assembly……………………………………………………………268
Removal…………………………………………………………………………268
Installation…………………………………………………………………….269
Differential gear assembly……………………………………………………………270
Disassembly……………………………………………………………………..270
Fine disassembly of pinion assembly…………………………………………….271
Disassembly of differential gear assembly……………………………………….273
Assembly………………………………………………………………………..274
Assembly of differential gear assembly………………………………………….274
Fine assembly of pinion assembly……………………………………………….276
Assembly of differential assembly………………………………………………277
Final drive assembly…………………………………………………………………282
Disassembly / assembly……………………………………………………………282
Steering cylinder assembly……………………………………………………………283
Removal…………………………………………………………………………283
Installation…………………………………………………………………….284
Steering valve assembly………………………………………………………………285
Removal…………………………………………………………………………285
Installation…………………………………………………………………….287
Slack adjuster assembly………………………………………………………………288
Removal…………………………………………………………………………288
Installation…………………………………………………………………….288
Hydraulic tank assembly………………………………………………………………289
Removal…………………………………………………………………………289
Installation…………………………………………………………………….291
PPC valve assembly…………………………………………………………………..292
Removal…………………………………………………………………………292
Installation…………………………………………………………………….293
Main control valve assembly…………………………………………………………..294
Removal (WF550-3)………………………………………………………………..294
Installation (WF550-3)……………………………………………………………297
Removal (WF550T-3)……………………………………………………………….297
Installation (WF550)……………………………………………………………..299
Disassembly……………………………………………………………………..300
WF550T-3…………………………………………………………………….300
Assembly………………………………………………………………………..304
WF550T-3…………………………………………………………………….304
Lift cylinder assembly……………………………………………………………….308
Removal (WF550T-3)……………………………………………………………….308
Installation (WF550T-3)…………………………………………………………..309
Boom, bucket and lift cylinders assembly……………………………………………….310
Disassembly……………………………………………………………………..310
Assembly………………………………………………………………………..312
Work equipment assembly………………………………………………………………315
Removal (WF550T-3)……………………………………………………………….315
Installation (WF550T-3)…………………………………………………………..316
Engine hood assembly…………………………………………………………………317
Removal…………………………………………………………………………317
Installation…………………………………………………………………….318
Floor frame assembly…………………………………………………………………319
Removal…………………………………………………………………………319
Installation…………………………………………………………………….322
Fuel tank assembly…………………………………………………………………..323
Removal…………………………………………………………………………323
Installation…………………………………………………………………….323
Air conditioner condenser assembly…………………………………………………….324
Removal…………………………………………………………………………324
Installation…………………………………………………………………….324
Reciver tank………………………………………………………………………..325
Removal…………………………………………………………………………325
Installation…………………………………………………………………….325
40 MAINTENANCE STANDARD………………………………………………………………….327
Engine mount………………………………………………………………………..328
Transmission mount…………………………………………………………………..329
Damper……………………………………………………………………………..330
Torque converter charging pump………………………………………………………..331
Torque converter, PTO………………………………………………………………..332
Transmission………………………………………………………………………..334
Transfer……………………………………………………………………………338
Main relief, torque converter relief valve……………………………………………..340
Lubrication relief valve……………………………………………………………..341
Drive shaft…………………………………………………………………………342
Center support………………………………………………………………………343
Differential………………………………………………………………………..344
Final drive…………………………………………………………………………346
Axle mount………………………………………………………………………….347
Center hinge pin…………………………………………………………………….348
Steering column……………………………………………………………………..350
Steering pump……………………………………………………………………….351
Steering valve………………………………………………………………………352
Steering cylinder mount………………………………………………………………353
Brake valve…………………………………………………………………………354
Slack adjuster………………………………………………………………………356
Brake………………………………………………………………………………357
Parking brake……………………………………………………………………….358
Hydraulik pump………………………………………………………………………359
WF550T-3………………………………………………………………………..359
WF550-3…………………………………………………………………………360
Switch, PPC pump…………………………………………………………………….361
PPC valve…………………………………………………………………………..362
WF550T-3………………………………………………………………………..362
WF550-3…………………………………………………………………………363
Main control valve…………………………………………………………………..364
WF550T-3………………………………………………………………………..364
WF550-3…………………………………………………………………………366
Cut-off valve……………………………………………………………………….368
WF550-3…………………………………………………………………………368
Hydraulic cylinders………………………………………………………………….370
WF550T-3………………………………………………………………………..370
WF550-3…………………………………………………………………………372
Work equipment linkage……………………………………………………………….374
WF550T-3………………………………………………………………………..374
WF550-3…………………………………………………………………………376
Bucket positioner and boom kick-out……………………………………………………378
WF550-3…………………………………………………………………………378
ROPS cab……………………………………………………………………………379
90 OTHERS………………………………………………………………………………381
Hydraulic circuit diagram for power train………………………………………………382
Brake circuit diagram………………………………………………………………..384
Electric circuit for cooling fan………………………………………………………386
Work equipment hydraulic circuit diagram (WF550T-3)……………………………………..387
Work equipment hydraulic circuit diagram (WF550-3)………………………………………389
Electric circuit diagram (1/4)………………………………………………………..391
Electric circuit diagram (2/4)………………………………………………………..392
Electric circuit diagram (3/4)………………………………………………………..393
Electric circuit diagram (4/4)………………………………………………………..394