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Komatsu WA150-6 Wheel Loader Shop Manual SEN04884-01 – PDF DOWNLOAD
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Komatsu WA150-6 Wheel Loader Shop Manual
SERIAL NUMBERS 80001 and up
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Description
Komatsu WA150-6 Wheel Loader Shop Manual SEN04884-01
FILE DETAILS:
Komatsu WA150-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA150-6
Serial Number: 80001 and up
Book Code: SEN04884-01
Language: English
Pages: 1244
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA150-6 Wheel Loader Shop Manual
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu WA150-6 Wheel Loader Shop Manual
COVER................................................................................................................................. 1 00 Index and foreword................................................................................................................. 3 100 Index......................................................................................................................... 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 200 Foreword and general information.............................................................................................. 17 Safety notice................................................................................................................. 18 How to read the shop manual................................................................................................... 23 Explanation of terms for maintenance standard................................................................................. 25 Handling of electric equipment and hydraulic component........................................................................ 27 Handling of connectors newly used for engines................................................................................. 36 How to read electric wire code................................................................................................ 39 Precautions when carrying out operation....................................................................................... 42 Method of disassembling and connecting push-pull type coupler................................................................. 45 Standard tightening torque table.............................................................................................. 48 Conversion table.............................................................................................................. 52 01 Specification...................................................................................................................... 59 100 Specification and technical data.............................................................................................. 59 Specification dimension drawing............................................................................................... 61 Specifications................................................................................................................ 62 Weight table.................................................................................................................. 66 Table of fuel, coolant and lubricants......................................................................................... 68 10 Structure, function and maintenance standard....................................................................................... 71 100 Engine and cooling system..................................................................................................... 71 Engine mount and transfer mount............................................................................................... 72 Damper........................................................................................................................ 73 Cooling system................................................................................................................ 74 Cooling system hydraulic piping diagram....................................................................................... 75 Cooling fan motor............................................................................................................. 77 200 Power train................................................................................................................... 87 Power train................................................................................................................... 89 Power train system diagram.................................................................................................... 90 Drive shaft................................................................................................................... 92 HST hydraulic piping diagram.................................................................................................. 93 HST pump...................................................................................................................... 94 HST motor..................................................................................................................... 103 Transfer...................................................................................................................... 110 Clutch solenoid valve......................................................................................................... 121 Axle.......................................................................................................................... 122 Differential.................................................................................................................. 124 Torque proportioning differential............................................................................................. 129 Limited slip differential..................................................................................................... 130 Final drive................................................................................................................... 134 300 Steering system............................................................................................................... 139 Steering piping diagram....................................................................................................... 141 Steering column............................................................................................................... 142 Priority valve................................................................................................................ 143 Orbit-roll valve.............................................................................................................. 146 Steering cylinder............................................................................................................. 154 Emergency steering piping diagram............................................................................................. 156 Emergency steering valve...................................................................................................... 157 400 Brake system.................................................................................................................. 161 Brake piping diagram.......................................................................................................... 163 Charge valve.................................................................................................................. 164 Brake valve................................................................................................................... 168 Inching valve................................................................................................................. 172 Accumulator (for brake)....................................................................................................... 173 Slack adjuster................................................................................................................ 174 Brake......................................................................................................................... 176 Parking brake control......................................................................................................... 181 Parking brake................................................................................................................. 182 500 Undercarriage and frame....................................................................................................... 185 Axle mount and center hinge pin............................................................................................... 186 Tires......................................................................................................................... 191 600 Hydraulic system.............................................................................................................. 193 Hydraulic component layout drawing............................................................................................ 194 Work equipment control lever linkage.......................................................................................... 196 Hydraulic tank................................................................................................................ 198 3-gear pump................................................................................................................... 200 Work equipment control valve.................................................................................................. 203 Work equipment PPC valve...................................................................................................... 243 Attachment PPC valve.......................................................................................................... 250 Lock valve.................................................................................................................... 252 2-way restrictor valve........................................................................................................ 253 Accumulator (for oil cooler circuit).......................................................................................... 254 Accumulator (for PPC circuit)................................................................................................. 255 Accumulator (for ECSS)........................................................................................................ 256 700 Work equipment................................................................................................................ 259 Work equipment linkage........................................................................................................ 260 Bucket........................................................................................................................ 262 Bucket positioner and boom kick-out........................................................................................... 264 Work equipment cylinder....................................................................................................... 270 800 Cab and its attachments....................................................................................................... 273 Cab........................................................................................................................... 275 901 Electrical system, Part 1..................................................................................................... 277 Machine monitor system........................................................................................................ 278 Machine monitor............................................................................................................... 282 902 Electrical system, Part 2..................................................................................................... 303 Electrical system (HST controller system)..................................................................................... 304 HST controller................................................................................................................ 320 ECSS system................................................................................................................... 321 KOMTRAX system................................................................................................................ 322 Engine starting circuit....................................................................................................... 324 Engine stopping circuit....................................................................................................... 326 Preheating circuit............................................................................................................ 327 Engine output derating function............................................................................................... 328 Automatic warm-up function.................................................................................................... 328 Parking brake circuit......................................................................................................... 330 Multi-function knob........................................................................................................... 332 Sensor........................................................................................................................ 333 20 Standard value table............................................................................................................... 341 100 Standard service value table.................................................................................................. 341 Standard service value table for engine....................................................................................... 342 Standard service value table for chassis...................................................................................... 343 30 Testing and adjusting.............................................................................................................. 351 101 Testing and adjusting, Part 1................................................................................................. 351 Tools for testing, adjusting, and troubleshooting............................................................................. 353 Testing engine speed.......................................................................................................... 358 Testing exhaust gas color..................................................................................................... 360 Testing exhaust temperature................................................................................................... 362 Adjusting valve clearance..................................................................................................... 363 Testing compression pressure.................................................................................................. 365 Testing blow-by pressure...................................................................................................... 367 Testing engine oil pressure................................................................................................... 368 Testing intake air (boost) pressure........................................................................................... 369 Handling fuel system equipment................................................................................................ 369 Releasing residual pressure in fuel system.................................................................................... 370 Testing fuel pressure......................................................................................................... 371 Testing fuel return rate and leakage.......................................................................................... 372 Bleeding air from fuel circuit................................................................................................ 375 Checking leakage in fuel system............................................................................................... 376 Handling cylinder cut-out mode operation...................................................................................... 377 Handling no-injection cranking operation...................................................................................... 377 Handling controller voltage circuit........................................................................................... 378 Check of muffler and muffler stack for looseness and damage................................................................... 378 Check of muffler function..................................................................................................... 379 Check of installed condition of cylinder head and manifolds................................................................... 379 Check of engine piping for damage and looseness............................................................................... 380 Testing and adjusting air conditioner compressor belt tension................................................................. 380 Testing and adjusting alternator belt tension................................................................................. 381 102 Testing and adjusting, Part 2................................................................................................. 383 Checking operating force of accelerator pedal................................................................................. 385 Checking directional lever.................................................................................................... 386 Testing and adjusting HST oil pressure........................................................................................ 387 Testing clutch control pressure............................................................................................... 391 Testing and adjusting steering wheel.......................................................................................... 392 Testing and adjusting steering oil pressure................................................................................... 394 Bleeding air from steering circuit............................................................................................ 396 Testing hydraulic fan......................................................................................................... 397 Testing brake pedal........................................................................................................... 399 Testing and adjusting brake pedal linkage..................................................................................... 400 Testing brake performance..................................................................................................... 401 Testing and adjusting accumulator charge pressure............................................................................. 402 Testing wheel brake oil pressure.............................................................................................. 404 Testing wear of brake disc.................................................................................................... 407 Bleeding air from wheel brake circuit......................................................................................... 408 Releasing residual pressure in brake accumulator circuit...................................................................... 409 Testing parking brake performance............................................................................................. 410 Testing and adjusting parking brake control cable............................................................................. 411 Testing and adjusting parking brake switch.................................................................................... 412 Testing and adjusting work equipment control lever............................................................................ 413 Testing and adjusting work equipment hydraulic pressure....................................................................... 414 Testing work equipment PPC oil pressure....................................................................................... 416 Bleeding air from hydraulic circuit........................................................................................... 418 Releasing remaining pressure in hydraulic circuit............................................................................. 418 Testing and adjusting bucket positioner....................................................................................... 419 Testing and adjusting boom kick-out switch.................................................................................... 421 Checking proximity switch operation pilot lamp................................................................................ 422 Procedure for testing diodes.................................................................................................. 423 Preparation work for troubleshooting for electric system...................................................................... 425 Starting KOMTRAX terminal operations.......................................................................................... 429 Indicator lamps of KOMTRAX terminal........................................................................................... 433 103 Testing and adjusting, Part 3................................................................................................. 437 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................ 438 Special functions of machine monitor (EMMS)................................................................................... 440 Pm clinic inspection chart.................................................................................................... 495 40 Troubleshooting.................................................................................................................... 499 100 Failure code table and fuse locations......................................................................................... 499 Failure codes table........................................................................................................... 500 Fuse locations................................................................................................................ 506 200 General information on troubleshooting........................................................................................ 511 Points to remember when troubleshooting....................................................................................... 512 Sequence of events in troubleshooting......................................................................................... 513 Testing before troubleshooting................................................................................................ 514 Classification and procedures of troubleshooting.............................................................................. 515 Information contained in troubleshooting table................................................................................ 518 Connection table for connector pin numbers.................................................................................... 520 T- branch box and T- branch adapter table..................................................................................... 556 301 Troubleshooting by failure code (Display of code), Part 1..................................................................... 561 Failure code [2G40ZG] Brake: Oil pressure reduction........................................................................... 562 Failure code [6091NX] HST filter: Clogging.................................................................................... 564 Failure code [989FN1] Travel speed: Overrun alarm............................................................................. 565 Failure code [AB00L6] Alternator R system: Hot short.......................................................................... 566 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage...................................... 568 Failure code [B@BAZG] Engine: Oil pressure reduction.......................................................................... 570 Failure code [B@BCNS] Engine: Overheat........................................................................................ 571 Failure code [B@BCZK] Engine: Low coolant level............................................................................... 572 Failure code [B@C6NS] Front brake: High oil temperature....................................................................... 574 Failure code [B@CRNS] HST: High oil temperature............................................................................... 575 302 Troubleshooting by failure code (Display of code), Part 2..................................................................... 577 Failure code [CA111] Abnormality in engine controller......................................................................... 579 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................... 582 Failure code [CA122] Charge pressure sensor high error........................................................................ 584 Failure code [CA123] Charge pressure sensor low error......................................................................... 586 Failure code [CA131] Throttle sensor high error............................................................................... 588 Failure code [CA132] Throttle sensor low error................................................................................ 590 Failure code [CA144] Coolant sensor high error................................................................................ 592 Failure code [CA145] Coolant sensor low error................................................................................. 594 Failure code [CA153] Charge temperature sensor high error..................................................................... 596 Failure code [CA154] Charge temperature sensor low error...................................................................... 598 Failure code [CA187] Sensor power supply 2 low error.......................................................................... 599 Failure code [CA221] Atmospheric pressure sensor high error................................................................... 600 Failure code [CA222] Atmospheric sensor low error............................................................................. 602 Failure code [CA227] Sensor power supply 2 high error......................................................................... 603 Failure code [CA234] Engine overspeed......................................................................................... 605 Failure code [CA238] Ne speed sensor power supply error....................................................................... 606 Failure code [CA271] IMV (IMA) Short circuit.................................................................................. 608 Failure code [CA272] IMV (IMA) Disconnection.................................................................................. 610 Failure code [CA322] Injector #1 open/short error............................................................................. 612 Failure code [CA324] Injector #3 open/short error............................................................................. 614 Failure code [CA331] Injector #2 open/short error............................................................................. 616 Failure code [CA332] Injector #4 open/short error............................................................................. 618 Failure code [CA351] Injectors drive circuit error............................................................................ 620 Failure code [CA352] Sensor power supply 1 low error.......................................................................... 622 Failure code [CA386] Sensor power supply 1 high error......................................................................... 624 303 Troubleshooting by failure code (Display of code), Part 3..................................................................... 627 Failure code [CA431] Idle validation switch error............................................................................. 628 Failure code [CA432] Idle validation action error............................................................................. 632 Failure code [CA435] Engine oil pressure switch error......................................................................... 636 Failure code [CA441] Battery voltage low error................................................................................ 637 Failure code [CA442] Battery voltage high error............................................................................... 638 Failure code [CA449] Common rail pressure high error 2........................................................................ 639 Failure code [CA451] Common rail pressure sensor high error................................................................... 640 Failure code [CA452] Common rail pressure sensor low error.................................................................... 642 Failure code [CA553] Common rail pressure high error 1........................................................................ 643 Failure code [CA559] Supply pump pressure very low error...................................................................... 644 Failure code [CA689] Engine Ne speed sensor error............................................................................. 648 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 650 Failure code [CA757] All continuous data lost error........................................................................... 651 Failure code [CA778] Engine Bkup speed sensor error........................................................................... 652 Failure code [CA1633] KOMNET datalink timeout error........................................................................... 654 Failure code [CA2185] Throttle sensor supply voltage high error............................................................... 656 Failure code [CA2186] Throttle sensor power supply low error.................................................................. 658 Failure code [CA2249] Supply pump pressure very low error 2................................................................... 660 Failure code [CA2311] Abnormality in IMV (IMA) solenoid....................................................................... 662 Failure code [CA2555] Intake heater relay disconnection error................................................................. 664 Failure code [CA2556] Intake heater relay short circuit error................................................................. 666 304 Troubleshooting by failure code (Display of code), Part 4..................................................................... 669 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short............................................................ 670 Failure code [D192KY] ECSS solenoid relay: Hot short.......................................................................... 672 Failure code [D1B0KA] HST safety relay: Disconnection......................................................................... 674 Failure code [D1B0KB] HST safety relay: Ground fault.......................................................................... 676 Failure code [D1B0KY] HST safety relay: Hot short............................................................................. 678 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection................................................................ 680 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection........................................................... 682 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection........................................................... 684 Failure code [DAJ0KK] HST controller power supply: Low voltage................................................................ 688 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality............................................................. 690 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault.............................................. 692 Failure code [DAJ1L6] HST controller main power line: Hot short............................................................... 694 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage........................................................... 696 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness.............................. 698 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............................... 700 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range............................................................. 702 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals................................. 704 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection............................................................ 705 Failure code [DAJRMA] HST controller: Disagreement in option selection........................................................ 711 305 Troubleshooting by failure code (Display of code), Part 5..................................................................... 713 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line................................................. 714 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality........................................................ 720 Failure code [DD1NLD] Fan reverse switch signal: Abnormality.................................................................. 722 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short.................................................. 724 Failure code [DDB6KB] Parking brake indicator signal: Ground fault............................................................ 726 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble.... 728 Failure code [DDB6L0] Parking brake reminder signal: Ground fault............................................................. 730 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short................................................. 732 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault............................................ 734 Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................................. 736 Failure code [DDE5MA] Emergency steering operation switch: Disconnection...................................................... 738 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short.................................................... 740 Failure code [DDK3KB] Directional selector switch: Ground fault............................................................... 742 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 744 Failure code [DDK6KY] FNR lever: Hot short.................................................................................... 748 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)............................................ 750 306 Troubleshooting by failure code (Display of code), Part 6..................................................................... 753 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.......................................... 754 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 758 Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 760 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.............................................................. 761 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short................................................... 762 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault..................................................... 764 Failure code [DHH1KY] HST oil pressure sensor: Hot short...................................................................... 766 Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................................... 768 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short.............................................................. 770 Failure code [DLT3KX] Travel speed sensor B: Abnormality...................................................................... 772 Failure code [DLT4KX] Travel speed sensor A: Abnormality...................................................................... 776 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality.................................................................. 778 Failure code [DV00KY] Alarm buzzer: Hot short................................................................................. 780 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault............................................................ 782 Failure code [DW26KY] Motor 2 solenoid: Hot short............................................................................. 784 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................................. 786 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault................................................ 788 307 Troubleshooting by failure code (Display of code), Part 7..................................................................... 791 Failure code [DX16KA] Fan EPC solenoid: Disconnection......................................................................... 792 Failure code [DX16KB] Fan EPC solenoid: Ground fault.......................................................................... 793 Failure code [DX16KY] Fan EPC solenoid: Hot short............................................................................. 794 Failure code [DX19KA] Motor 1 solenoid: Disconnection......................................................................... 796 Failure code [DX19KB] Motor 1 solenoid: Ground fault.......................................................................... 798 Failure code [DX19KY] Motor 1 solenoid: Hot short............................................................................. 800 Failure code [DX20KA] Clutch EPC solenoid: Disconnection...................................................................... 802 Failure code [DX20KB] Clutch EPC solenoid: Ground fault....................................................................... 804 Failure code [DX20KY] Clutch EPC solenoid: Hot short.......................................................................... 806 Failure code [DXH7KB] Reverse solenoid: Ground fault.......................................................................... 808 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................... 810 Failure code [DXH8KB] Forward solenoid: Ground fault.......................................................................... 812 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................... 814 Failure code [J141N1] Steering pump: Overrun alarm............................................................................ 816 Failure code [M100N1] HST pump: Overrun alarm................................................................................. 816 Failure code [M400N1] Motor 1: Overrun alarm.................................................................................. 817 400 Troubleshooting of electrical system (E-mode)................................................................................. 819 E-1 Engine does not start..................................................................................................... 821 E-2 Preheater does not operate normally....................................................................................... 828 E-3 Travel speed is low or high............................................................................................... 832 E-4 ECSS does not operate..................................................................................................... 838 E-5 ECSS keeps operating...................................................................................................... 841 E-6 Defective boom kick-out function and cancellation......................................................................... 844 E-7 Defective bucket positioner function and cancellation..................................................................... 848 E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 852 E-9 Travel direction selection system does not function....................................................................... 856 E-10 Fan does not reverse..................................................................................................... 860 E-11 Fan keeps rotating in reverse............................................................................................ 864 E-12 Wiper does not operate................................................................................................... 866 E-13 Windshield washer does not operate....................................................................................... 870 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off......................................................... 874 E-15 Working lamp does not light up or go off................................................................................. 882 E-16 Turn signal lamp and hazard lamp do not light up or go off............................................................... 887 E-17 Brake lamp does not light or it keeps lighting up........................................................................ 894 E-18 Backup lamp does not light or it keeps lighting up....................................................................... 896 E-19 Backup alarm does not sound or it keeps sounding......................................................................... 899 E-20 Horn does not sound or it keeps sounding................................................................................. 902 E-21 Alarm buzzer does not sound or it keeps sounding......................................................................... 904 E-22 The KOMTRAX system does not work properly................................................................................ 906 500 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................... 909 Method of using troubleshooting chart......................................................................................... 911 Failure code and cause table.................................................................................................. 914 H-1 The machine does not start................................................................................................ 916 H-2 The travel speed is slow.................................................................................................. 917 H-3 The traction force is weak................................................................................................ 918 H-4 Engine stalls when traveling or engine speed drops excessively............................................................ 919 H-5 Speed range is not shifted................................................................................................ 920 H-6 The steering wheel does not turn.......................................................................................... 921 H-7 The steering wheel is heavy............................................................................................... 922 H-8 Steering wheel shakes or jerks............................................................................................ 923 H-9 Machine deviates naturally to one side when traveling..................................................................... 923 H-10 The brake does not work or does not work well............................................................................ 924 H-11 The brake is not released or is dragged.................................................................................. 925 H-12 The lift arm does not rise or lower...................................................................................... 926 H-13 The lift arm moves slowly or the lift arm rising force is insufficient................................................... 927 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 928 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises above the ground).................................... 928 H-16 Hydraulic drifts of the lift arm occur often............................................................................. 928 H-17 The lift arm wobbles during operation.................................................................................... 928 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily................................ 929 H-19 The bucket does not tilt back............................................................................................ 930 H-20 The bucket moves slowly or the tilting-back force is insufficient........................................................ 931 H-21 The bucket comes to operate slowly in the midst of tilting-back.......................................................... 932 H-22 The bucket cylinder cannot hold down the bucket.......................................................................... 932 H-23 Hydraulic drifts of the bucket occur often............................................................................... 932 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)................................... 932 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily................................... 933 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy............................................. 933 H-27 The ECSS does not operate and machine pitches and bounces................................................................ 934 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................................. 935 600 Troubleshooting of engine (S-mode)............................................................................................ 937 Method of using troubleshooting charts........................................................................................ 938 S-1 Starting performance is poor.............................................................................................. 942 S-2 Engine does not start..................................................................................................... 943 S-3 Engine does not pick up smoothly.......................................................................................... 946 S-4 Engine stops during operations............................................................................................ 947 S-5 Engine does not rotate smoothly........................................................................................... 948 S-6 Engine lacks output (or lacks power)...................................................................................... 949 S-7 Exhaust smoke is black (incomplete combustion)............................................................................ 950 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................... 951 S-9 Oil becomes contaminated quickly.......................................................................................... 952 S-10 Fuel consumption is excessive............................................................................................ 953 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................... 954 S-12 Oil pressure drops....................................................................................................... 955 S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 956 S-14 Coolant temperature becomes too high (overheating)....................................................................... 957 S-15 Abnormal noise is made................................................................................................... 958 S-16 Vibration is excessive................................................................................................... 959 50 Disassembly and assembly........................................................................................................... 961 100 General information on disassembly and assembly............................................................................... 961 How to read this manual....................................................................................................... 962 Coating materials list........................................................................................................ 964 Special tools list............................................................................................................ 967 Sketches of special tools..................................................................................................... 970 200 Engine and cooling system..................................................................................................... 977 Removal and installation of fuel supply pump assembly......................................................................... 978 Removal and installation of fuel injector assembly............................................................................ 982 Removal and installation of engine hood assembly.............................................................................. 986 Removal and installation of cylinder head assembly............................................................................ 988 Removal and installation of radiator.......................................................................................... 998 Removal and installation of air aftercooler...................................................................................1001 Removal and installation of hydraulic oil cooler assembly.....................................................................1003 Removal and installation of engine and HST pump and 3-gear pump assembly......................................................1005 Removal and installation of engine front oil seal.............................................................................1010 Removal and installation of engine rear oil seal..............................................................................1013 Removal and installation of cooling fan and fan motor assembly................................................................1016 Removal and installation of fuel tank assembly................................................................................1019 300 Power train...................................................................................................................1025 Removal and installation of transfer and HST motor assembly...................................................................1026 Disassembly and assembly of transfer assembly.................................................................................1029 Removal and installation of parking brake assembly............................................................................1049 Disassembly and assembly of parking brake assembly............................................................................1050 Removal and installation of front axle assembly...............................................................................1054 Removal and installation of rear axle assembly................................................................................1056 Disassembly and assembly of axle housing assembly.............................................................................1058 Disassembly and assembly of differential assembly.............................................................................1069 400 Undercarriage and frame.......................................................................................................1093 Removal and installation of center hinge pin..................................................................................1094 Removal and installation of counterweight.....................................................................................1102 500 Hydraulic system..............................................................................................................1105 Removal and installation of transfer and HST pump and 3-gear pump assembly....................................................1106 Removal and installation of HST motor 1 assembly..............................................................................1110 Removal and installation of HST motor 2 assembly..............................................................................1113 Removal and installation of work equipment control valve assembly.............................................................1115 Removal and installation of hydraulic tank assembly...........................................................................1118 Disassembly and assembly of hydraulic cylinder assembly.......................................................................1120 600 Work equipment................................................................................................................1125 Removal and installation of work equipment assembly...........................................................................1126 700 Cab and its attachments.......................................................................................................1135 Removal and installation of operator's cab and floor frame assembly...........................................................1136 Removal and installation of operator's cab glass (Stuck glass)................................................................1141 Removal and installation of air conditioner unit..............................................................................1149 800 Electrical system.............................................................................................................1157 Removal and installation of monitor panel.....................................................................................1158 Removal and installation of engine controller assembly........................................................................1160 Removal and installation of HST controller assembly...........................................................................1162 Removal and installation of KOMTRAX terminal assembly.........................................................................1163 80 Appendix...........................................................................................................................1165 100 Air conditioner...............................................................................................................1165 Structure and function........................................................................................................1168 Air conditioner component.................................................................................................1168 Configuration and function of refrigerating cycle.........................................................................1170 Outline of refrigerating cycle............................................................................................1171 Air conditioner unit......................................................................................................1174 Functions of major components in the air conditioner unit.................................................................1175 Blower and intake unit....................................................................................................1176 Compressor................................................................................................................1177 Condenser.................................................................................................................1178 Receiver drier............................................................................................................1179 Air conditioner control panel.............................................................................................1180 Testing, adjusting and troubleshooting........................................................................................1182 Caution about refrigerant.................................................................................................1182 Troubleshooting procedure.................................................................................................1183 Block diagram and circuit diagram of control system.......................................................................1184 Detail of air conditioner unit............................................................................................1187 Arrangement of connector pins.............................................................................................1188 Part and connector locations..............................................................................................1189 Testing with self-diagnosis function (indication on control panel)........................................................1191 Testing temperature control...............................................................................................1192 Testing Recirc/Fresh changeover...........................................................................................1193 Testing evaporator temperature sensor electrically........................................................................1195 Testing relays............................................................................................................1196 Troubleshooting chart 1...................................................................................................1197 Troubleshooting chart 2...................................................................................................1198 Troubleshooting for electrical system (E mode)............................................................................1201 E-1 Power supply system (Air conditioner does not operate)............................................................1202 E-2 Compressor or refrigerant system (Air is not cooled)..............................................................1205 E-3 Blower motor system (No air comes out or air flow is abnormal)....................................................1208 E-4 Temperature cannot be controlled..................................................................................1211 E-5 Recirc/Fresh cannot be changed over...............................................................................1214 Troubleshooting with gauge pressure.......................................................................................1216 Connection of service tool................................................................................................1218 Precautions for connecting air conditioner piping.........................................................................1219 Handling of compressor oil................................................................................................1220 1. Control of compressor oil..........................................................................................1220 2. Adding of compressor oil...........................................................................................1220 3. Compressor replacement.............................................................................................1221 4. Applying compressor oil for O-ring.................................................................................1221 90 Diagrams and drawings..............................................................................................................1223 100 Hydraulic diagrams and drawings...............................................................................................1223 Hydraulic circuit diagram.....................................................................................................1225 200 Electrical diagrams and drawings..............................................................................................1228 Common electrical circuit diagram.............................................................................................1230 Connector list and stereogram.................................................................................................1242
KOMATSU WA150-6 WHEEL LOADER SHOP MANUAL SEN04884-01 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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