Komatsu Wheel Loader WA40 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA40, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA40-1 workshop service repair manual includes:
* 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: 488 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEAM03630102 - Wheel Loader WA40-1 Operation & Maintenance Manual.pdf
SEBM03630101 - Wheel Loader WA40-1 Shop Manual.pdf
MAIN SECTIONS
SEAM03630102 - Wheel Loader WA40-1 Operation & Maintenance Manual....2
COVER....2
FOREWORD....3
BREAKING IN YOUR NEW MACHINE....4
CONTENTS....5
SAFETY HINTS....6
GENERAL LOCATIONS AND SPECIFICATIONS....18
OPERATOR'S COMPARTMENT....19
INSTRUMENTS AND CONTROLS....21
OIL FILLER AND GAUGE POSITIONS....34
CHECK BEFORE STARTING....35
OPERATING YOUR MACHINE....40
COLD WEATHER OPERATION....49
BUCKET OPERATION....52
HOW TO USE INCHING PEDAL....56
TIRE REPLACEMENT....59
HANDLING OF BATTERY....60
TRAVELING WITH NO LOAD FOR LONG DISTANCE....63
TRANSPORTATION....64
PERIODIC MAINTENANCE....66
PRECAUTIONS FOR MAINTENANCE....67
PERIODIC REPLACEMENT OF PARTS FOR SAFETY....75
MAINTENANCE TABLE....76
EVERY 50 HOURS SERVICE....78
EVERY 250 HOURS SERVICE....79
EVERY 500 HOURS SERVICE....85
EVERY 1000 HOURS SERVICE....89
EVERY 2000 HOURS SERVICE....93
WHEN REQUIRED....94
ADJUSTMENT....99
STORAGE....101
SERVICE METER....103
MACHINE AND ENGINE SERIAL NUMBERS....104
FUEL,COOLANT AND LUBRICANTS....105
OPTION....109
GENERAL LOCATIONS AND SPECIFICATIONS....110
OPERATOR'S COMPARTMENT....111
INSTRUMENTS AND CONTROLS....113
OIL FILLER AND GAUGE POSITIONS....123
CHECK BEFORE STARTING....125
OPERATING YOUR MACHINE....127
TRAVELING WITH NO LOAD FOR LONG DISTANCE....133
MAINTENANCE TABLE....134
EVERY 250 HOURS SERVICE....136
WHEN REQUIRED....137
ADJUSTMENT....140
FUEL,COOLANT AND LUBRICANTS....143
SEBM03630101 - Wheel Loader WA40-1 Shop Manual....144
COVER....144
CONTENTS....145
01 GENERAL....156
GENERAL VIEW....157
GENERAL ASSEMBLY DRAWING....158
SPECIFICATIONS....159
ENGINE ASSEMBLY DRAWING....161
ENGINE SPECIFICATIONS....162
WEIGHT OF COMPONENT PARTS....163
TABLE OF OIL AND COOLANT CAPACITIES....164
10 ENGINE....165
11 STRUCTURE AND FUNCTION....165
ENGINE MOUNT....166
RADIATOR....167
FUEL CONTROL LINKAGE....168
FUEL PIPING....169
FUEL PIPING (OPTION)....170
13 DISASSEMBLY AND ASSEMBLY....171
STARTING MOTOR....172
REMOVAL....172
INSTALLATION....172
STARTING MOTOR (OPTION)....173
REMOVAL....173
INSTALLATION....173
ALTERNATOR....174
REMOVAL....174
INSTALLATION....174
FUEL INJECTION PUMP....175
REMOVAL....175
INSTALLATION....178
FUEL INJECTION PUMP (OPTION)....182
REMOVAL ....182
INSTALLATION....185
NOZZLE HOLDER....189
REMOVAL....189
INSTALLATION....189
WATER PUMP....190
REMOVAL....190
INSTALLATION....191
WATER PUMP (OPTION)....192
REMOVAL....192
INSTALLATION....193
CYLINDER HEAD....194
REMOVAL....194
INSTALLATION....198
CYLINDER HEAD (OPTION)....203
REMOVAL....203
INSTALLATION....207
RADIATOR....212
REMOVAL....212
INSTALLATION....212
ENGINE,TRANSMISSION....213
REMOVAL....213
INSTALLATION....220
ENGINE,TRANSMISSION (OPTION)....228
REMOVAL....228
INSTALLATION....235
ENGINE AND TRANSMISSION....243
SEPARATION....243
CONNECTION....243
20 POWER TRAIN....244
21 STRUCTURE AND FUNCTION....244
TRANSMISSION SYSTEM....245
1.SCHEMATIC OF TRANSMISSION SYSTEM....245
2.TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....246
3.SCHEMATIC OF TRANSMISSION SYSTEM (OPTION)....247
4.TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM (OPTION)....248
5.TRANSMISSION....249
6.TRANSMISSION PUMP....255
7.TRANSFER....256
8.TRANSMISSION CONTROL VALVE....257
9.TRANSMISSION CONTROL LINKAGE....261
10.TRANSMISSION CONTROL LINKAGE (OPTION)....262
11.TRANSMISSION OIL COOLER HYDRAULIC PIPING....263
DRIVE SYSTEM....264
1.DRIVE SHAFT....264
2.AXLE....265
3.AXLE (OPTION)....267
4.WHEEL....269
5.WHEEL (OPTION)....270
23 DISASSEMBLY AND ASSEMBLY....271
TRANSMISSION PUMP....272
REMOVAL....272
INSTALLATION....272
TRANSMISSION PUMP (OPTION)....273
REMOVAL....273
INSTALLATION....273
TRANSMISSION....274
DISASSEMBLY (1/2)....274
DISASSEMBLY (2/2)....281
TRANSMISSION....291
ASSEMBLY (1/2)....291
ASSEMBLY (2/2)....304
SELECTOR AND INCHING VALVE....313
REMOVAL....313
INSTALLATION....313
SELECTOR AND INCHING VALVE (OPTION)....314
REMOVAL....314
INSTALLATION....314
SELECTOR AND INCHING VALVE....315
DISASSEMBLY....315
ASSEMBLY....317
MODULATING VALVE....320
REMOVAL....320
INSTALLATION....320
DISASSEMBLY....321
ASSEMBLY....322
FRONT AXLE....323
REMOVAL....323
INSTALLATION....323
REAR AXLE....324
REMOVAL....324
INSTALLATION....324
REAR AXLE (OPTION)....325
REMOVAL....325
INSTALLATION....325
AXLE....326
DISASSEMBLY....326
ASSEMBLY....331
AXLE (OPTION)....341
DISASSEMBLY....341
ASSEMBLY....346
24 MAINTENANCE STANDARD....356
TRANSMISSION....357
TRANSMISSION CONTROL VALVE....359
TRANSMISSION PUMP....361
DRIVE SHAFT....362
AXLE....363
AXLE (OPTION)....364
40 STEERING SYSTEM....365
41 STRUCTURE AND FUNCTION....365
STEERING SYSTEM....366
1.STEERING PIPING....366
2.STEERING WHEEL....367
3.STEERING PUMP....368
4.STEERING VALVE....369
5.STEERING CYLINDER....378
6.CENTER HINGE PIN....379
STEERING SYSTEM (OPTION)....380
1.SCHEMATIC OF STEERING SYSTEM....380
2.STEERING CIRCUIT DIAGRAM....381
3.STEERING VALVE ASSEMBLY....382
43 DISASSEMBLY AND ASSEMBLY....387
STEERING PUMP....388
REMOVAL....388
INSTALLATION....388
STEERING PUMP (OPTION)....389
REMOVAL....389
INSTALLATION....389
STEERING VALVE....390
REMOVAL....390
INSTALLATION....390
STEERING VALVE (OPTION)....391
REMOVAL....391
INSTALLATION....391
STEERING CYLINDER....392
REMOVAL....392
INSTALLATION....392
44 MAINTENANCE STANDARD....393
STEERING WHEEL....394
CENTER HINGE PIN....395
50 BRAKE SYSTEM....396
51 STRUCTURE AND FUNCTION....396
BRAKE SYSTEM....397
1.BRAKE AND INCHING CONTROL LINKAGE....397
2.BRAKE AND INCHING CONTROL LINKAGE (OPTION)....398
3.BRAKE MASTER CYLINDER....400
4.BRAKE MASTER CYLINDER (OPTION)....402
5.CENTER BRAKE....404
6.WHEEL BRAKE (OPTION)....405
7.PARKING BRAKE CONTROL LINKAGE....406
53 DISASSEMBLY AND ASSEMBLY....408
PARKING BRAKE....409
REMOVAL....409
INSTALLATION....410
PARKING BRAKE (OPTION)....411
REMOVAL....411
INSTALLATION....412
BRAKE MASTER CYLINDER....413
REMOVAL....413
INSTALLATION....413
BRAKE MASTER CYLINDER (OPTION)....414
REMOVAL....414
INSTALLATION....414
BRAKE CALIPER (OPTION)....415
REMOVAL....415
INSTALLATION....415
DISASSEMBLY....416
ASSEMBLY....416
54 MAINTENANCE STANDARD....417
CENTER BRAKE....418
60 WORK EQUIPMENT SYSTEM....419
61 STRUCTURE AND FUNCTION....419
HYDRAULIC UNITS....420
WORK EQUIPMENT SYSTEM....421
1.WORK EQUIPMENT HYDRAULIC PIPING....421
2.SCHEMATIC OF WORK EQUIPMENT AND STEERING SYSTEM....422
3.WORK EQUIPMENT AND STEERING HYDRAULIC CIRCUIT DIAGRAM....423
4.WORK EQUIPMENT PUMP....424
5.OIL FILTER....425
6.WORK EQUIPMENT CONTROL VALVE....426
7.HYDRAULIC CYLINDER....432
8.WORK EQUIPMENT CONTROL LINKAGE....433
63 DISASSEMBLY AND ASSEMBLY....437
MAIN CONTROL VALVE....438
REMOVAL....438
INSTALLATION....439
DISASSEMBLY....440
ASSEMBLY....442
LIFT CYLINDER....444
REMOVAL....444
INSTALLATION....444
LIFT CYLINDER (OPTION)....445
REMOVAL....445
INSTALLATION....445
DUMP CYLINDER....446
REMOVAL....446
INSTALLATION....446
HYDRAULIC CYLINDER....447
DISASSEMBLY....447
ASSEMBLY....449
WORK EQUIPMENT ....452
REMOVAL....452
INSTALLATION....452
DISASSEMBLY....453
ASSEMBLY....453
64 MAINTENANCE STANDARD....454
HYDRAULIC PUMP....455
WORK EQUIPMENT CONTROL VALVE....456
HYDRAULIC CYLINDER....458
WORK EQUIPMENT....460
BUCKET....462
80 ELECTRIC AND ELECTRONIC SYSTEM....463
81 STRUCTURE AND FUNCTION....463
ELECTRIC WIRING DIAGRAM....464
ELECTRIC WIRING DIAGRAM (OPTION)....465
ELECTRIC CIRCUIT DIAGRAM....466
ELECTRIC CIRCUIT DIAGRAM (OPTION)....467
90 OTHERS....468
91 STRUCTURE AND FUNCTION....468
OPERATOR'S CAB (OPTION)....469
OPERATOR'S CAB HEATER (OPTION)....472
93 DISASSEMBLY AND ASSEMBLY....473
INSTRUMENT PANEL,FRAME....474
REMOVAL....474
INSTALLATION....477
INSTRUMENT PANEL,FRAME (OPTION)....480
REMOVAL....480
INSTALLATION....484
CAB (OPTION)....488
REMOVAL....488
INSTALLATION....488
