Komatsu WA150-6 Wheel Loader Shop Manual SEN04885-11 PDF

Description

Komatsu WA150-6 Wheel Loader Shop Manual SEN04885-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA150-6 Wheel Loader Shop Manual SEN04885-11 – PDF DOWNLOAD 

Language : English
Pages : 1246
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA150-6 Wheel Loader Shop Manual SEN04885-11 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

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
400 Brake system 157
Brake piping diagram 159
Charge valve 160
Brake valve 164
Inching valve 168
Accumulator (for brake) 169
Slack adjuster 170
Brake 172
Parking brake control 177
Parking brake 178
500 Undercarriage and frame 181
Axle mount and center hinge pin 182
600 Hydraulic system 189
Hydraulic component layout drawing 190
Work equipment control lever linkage 192
Hydraulic tank 194
3-gear pump 196
Work equipment control valve 199
Work equipment PPC valve 239
Attachment PPC valve 246
Lock valve 248
2-way restrictor valve 249
Accumulator (for oil cooler circuit) 250
Accumulator (for PPC circuit) 251
Accumulator (for ECSS) 252
700 Work equipment 255
Work equipment linkage 256
Bucket 258
Bucket positioner and boom kick-out 260
Work equipment cylinder 266
800 Cab and its attachments 269
Cab 271
901 Electrical system, Part 1 273
Machine monitor system 274
Machine monitor 278
902 Electrical system, Part 2 299
Electrical system (HST controller system) 300
HST controller 316
ECSS system 317
KOMTRAX system 318
Engine starting circuit 320
Engine stopping circuit 322
Preheating circuit 323
Engine output derating function 324
Automatic warm-up function 324
Parking brake circuit 326
Multi-function knob 328
Sensor 329
20 Standard value table 337
100 Standard service value table 337
Standard service value table for engine 338
Standard service value table for chassis 339
30 Testing and adjusting 347
101 Testing and adjusting, Part 1 347
Precautions before work 349
Tools for testing, adjusting, and troubleshooting 350
Testing engine speed 355
Testing exhaust gas color 357
Testing exhaust temperature 359
Adjusting valve clearance 360
Testing compression pressure 362
Testing blow-by pressure 364
Testing engine oil pressure 365
Testing intake air (boost) pressure 366
Handling fuel system equipment 366
Releasing residual pressure in fuel system 367
Testing fuel pressure 368
Testing fuel return rate and leakage 369
Bleeding air from fuel circuit 372
Checking leakage in fuel system 373
Handling cylinder cut-out mode operation 374
Handling no-injection cranking operation 374
Handling controller voltage circuit 375
Check of muffler and muffler stack for looseness and damage 375
Check of muffler function 376
Check of installed condition of cylinder head and manifolds 376
Check of engine piping for damage and looseness 377
Testing and adjusting air conditioner compressor belt tension 377
Testing and adjusting alternator belt tension 378
102 Testing and adjusting, Part 2 381
Checking operating force of accelerator pedal 383
Checking directional lever 384
Testing and adjusting HST oil pressure 385
Testing clutch control pressure 390
Testing and adjusting steering wheel 391
Testing and adjusting steering oil pressure 393
Bleeding air from steering circuit 395
Testing hydraulic fan 396
Testing brake pedal 398
Testing and adjusting brake pedal linkage 399
Testing brake performance 400
Testing and adjusting accumulator charge pressure 401
Testing wheel brake oil pressure 403
Testing wear of brake disc 406
Bleeding air from wheel brake circuit 407
Releasing residual pressure in brake accumulator circuit 408
Testing parking brake performance 409
Testing and adjusting parking brake control cable 410
Testing and adjusting parking brake switch 411
Testing and adjusting work equipment control lever 412
Testing and adjusting work equipment hydraulic pressure 413
Testing work equipment PPC oil pressure 415
Bleeding air from hydraulic circuit 417
Releasing remaining pressure in hydraulic circuit 417
Testing and adjusting bucket positioner 418
Testing and adjusting boom kick-out switch 420
Checking proximity switch operation pilot lamp 421
Procedure for testing diodes 422
Preparation work for troubleshooting for electric system 424
Starting KOMTRAX terminal operations 428
Indicator lamps of KOMTRAX terminal 432
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 494
40 Troubleshooting 497
100 Failure code table and fuse locations 497
Precautions before work 498
Failure codes table 499
Fuse locations 505
200 General information on troubleshooting 509
Points to remember when troubleshooting 510
Sequence of events in troubleshooting 511
Testing before troubleshooting 512
Classification and procedures of troubleshooting 513
Information contained in troubleshooting table 516
Connection table for connector pin numbers 518
T- branch box and T- branch adapter table 554
301 Troubleshooting by failure code (Display of code), Part 1 559
Failure code [2G40ZG] Brake: Oil pressure reduction 560
Failure code [6091NX] HST filter: Clogging 562
Failure code [989FN1] Travel speed: Overrun alarm 563
Failure code [AB00L6] Alternator R system: Hot short 564
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage 566
Failure code [B@BAZG] Engine: Oil pressure reduction 568
Failure code [B@BCNS] Engine: Overheat 569
Failure code [B@BCZK] Engine: Low coolant level 570
Failure code [B@C6NS] Front brake: High oil temperature 572
Failure code [B@CRNS] HST: High oil temperature 573
302 Troubleshooting by failure code (Display of code), Part 2 575
Failure code [CA111] Abnormality in engine controller 577
Failure code [CA115] Engine Ne or Bkup speed sensor error 580
Failure code [CA122] Charge pressure sensor high error 582
Failure code [CA123] Charge pressure sensor low error 584
Failure code [CA131] Throttle sensor high error 586
Failure code [CA132] Throttle sensor low error 588
Failure code [CA144] Coolant sensor high error 590
Failure code [CA145] Coolant sensor low error 592
Failure code [CA153] Charge temperature sensor high error 594
Failure code [CA154] Charge temperature sensor low error 596
Failure code [CA187] Sensor power supply 2 low error 597
Failure code [CA221] Atmospheric pressure sensor high error 598
Failure code [CA222] Atmospheric sensor low error 600
Failure code [CA227] Sensor power supply 2 high error 601
Failure code [CA234] Engine overspeed 603
Failure code [CA238] Ne speed sensor power supply error 604
Failure code [CA271] IMV (IMA) Short circuit 606
Failure code [CA272] IMV (IMA) Disconnection 608
Failure code [CA322] Injector #1 open/short error 610
Failure code [CA324] Injector #3 open/short error 612
Failure code [CA331] Injector #2 open/short error 614
Failure code [CA332] Injector #4 open/short error 616
Failure code [CA351] Injectors drive circuit error 618
Failure code [CA352] Sensor power supply 1 low error 620
Failure code [CA386] Sensor power supply 1 high error 622
303 Troubleshooting by failure code (Display of code), Part 3 625
Failure code [CA431] Idle validation switch error 626
Failure code [CA432] Idle validation action error 630
Failure code [CA435] Engine oil pressure switch error 634
Failure code [CA441] Battery voltage low error 635
Failure code [CA442] Battery voltage high error 636
Failure code [CA449] Common rail pressure high error 2 637
Failure code [CA451] Common rail pressure sensor high error 638
Failure code [CA452] Common rail pressure sensor low error 640
Failure code [CA553] Common rail pressure high error 1 641
Failure code [CA559] Supply pump pressure very low error 642
Failure code [CA689] Engine Ne speed sensor error 646
Failure code [CA731] Engine Bkup speed sensor phase error 648
Failure code [CA757] All continuous data lost error 649
Failure code [CA778] Engine Bkup speed sensor error 650
Failure code [CA1633] KOMNET datalink timeout error 652
Failure code [CA2185] Throttle sensor supply voltage high error 654
Failure code [CA2186] Throttle sensor power supply low error 656
Failure code [CA2249] Supply pump pressure very low error 2 658
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 660
Failure code [CA2555] Intake heater relay disconnection error 662
Failure code [CA2556] Intake heater relay short circuit error 664
304 Troubleshooting by failure code (Display of code), Part 4 667
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short 668
Failure code [D192KY] ECSS solenoid relay: Hot short 670
Failure code [D1B0KA] HST safety relay: Disconnection 672
Failure code [D1B0KB] HST safety relay: Ground fault 674
Failure code [D1B0KY] HST safety relay: Hot short 676
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection 678
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection 680
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection 682
Failure code [DAJ0KK] HST controller power supply: Low voltage 684
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality 686
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault 688
Failure code [DAJ1L6] HST controller main power line: Hot short 690
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage 692
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness 694
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault 696
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range 698
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals 700
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection 701
Failure code [DAJRMA] HST controller: Disagreement in option selection 706
305 Troubleshooting by failure code (Display of code), Part 5 709
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line 710
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality 714
Failure code [DD1NLD] Fan reverse switch signal: Abnormality 716
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short 718
Failure code [DDB6KB] Parking brake indicator signal: Ground fault 720
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble 722
Failure code [DDB6L0] Parking brake reminder signal: Ground fault 724
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short 726
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault 728
Failure code [DDD7KY] Travel speed control dial signal: Hot short 730
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault 732
Failure code [DDK6KY] FNR lever: Hot short 736
306 Troubleshooting by failure code (Display of code), Part 6 739
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault 740
Failure code [DF10KB] Travel speed range selector switch: Hot short 744
Failure code [DGH1KX] HST oil temperature sensor: Ground fault 746
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault 747
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short 748
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault 750
Failure code [DHH1KY] HST oil pressure sensor: Hot short 752
Failure code [DHTCL6] HST filter clogging sensor: Functional defect 754
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short 756
Failure code [DLT3KX] Travel speed sensor B: Abnormality 758
Failure code [DLT4KX] Travel speed sensor A: Abnormality 762
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality 764
Failure code [DV00KY] Alarm buzzer: Hot short 766
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault 768
Failure code [DW26KY] Motor 2 solenoid: Hot short 770
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short 772
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault 774
307 Troubleshooting by failure code (Display of code), Part 7 777
Failure code [DX16KA] Fan EPC solenoid: Disconnection 778
Failure code [DX16KB] Fan EPC solenoid: Ground fault 779
Failure code [DX16KY] Fan EPC solenoid: Hot short 780
Failure code [DX19KA] Motor 1 solenoid: Disconnection 782
Failure code [DX19KB] Motor 1 solenoid: Ground fault 784
Failure code [DX19KY] Motor 1 solenoid: Hot short 786
Failure code [DX20KA] Clutch EPC solenoid: Disconnection 788
Failure code [DX20KB] Clutch EPC solenoid: Ground fault 790
Failure code [DX20KY] Clutch EPC solenoid: Hot short 792
Failure code [DXH7KB] Reverse solenoid: Ground fault 794
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short 796
Failure code [DXH8KB] Forward solenoid: Ground fault 798
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short 800
Failure code [J141N1] Steering pump: Overrun alarm 802
Failure code [M100N1] HST pump: Overrun alarm 802
Failure code [M400N1] Motor 1: Overrun alarm 803
400 Troubleshooting of electrical system (E-mode) 805
E-1 Engine does not start 807
E-2 Preheater does not operate normally 814
E-3 Travel speed is low or high 818
E-4 ECSS does not operate 824
E-5 ECSS keeps operating 827
E-6 Defective boom kick-out function and cancellation 830
E-7 Defective bucket positioner function and cancellation 834
E-8 Defective lift arm FLOATING holding function and cancellation 838
E-9 Travel direction selection system does not function 842
E-10 Fan does not reverse 846
E-11 Fan keeps rotating in reverse 850
E-12 Wiper does not operate 852
E-13 Windshield washer does not operate 856
E-14 Headlamp, clearance lamp, tail lamp and license lamp do not light up or go off 860
E-15 Working lamp does not light up or go off 868
E-16 Turn signal lamp and hazard lamp do not light up or go off 873
E-17 Brake lamp does not light or it keeps lighting up 880
E-18 Backup lamp does not light or it keeps lighting up 882
E-19 Backup alarm does not sound or it keeps sounding 885
E-20 Horn does not sound or it keeps sounding 888
E-21 Alarm buzzer does not sound or it keeps sounding 890
E-22 The KOMTRAX system does not work properly 892
500 Troubleshooting of hydraulic and mechanical system (H-mode) 895
Method of using troubleshooting chart 897
Failure code and cause table 900
H-1 The machine does not start 902
H-2 The travel speed is slow 903
H-3 The traction force is weak 904
H-4 Engine stalls when traveling or engine speed drops excessively 905
H-5 Speed range is not shifted 906
H-6 The steering wheel does not turn 907
H-7 The steering wheel is heavy 908
H-8 Steering wheel shakes or jerks 909
H-9 Machine deviates naturally to one side when traveling 909
H-10 The brake does not work or does not work well 910
H-11 The brake is not released or is dragged 911
H-12 The lift arm does not rise or lower 912
H-13 The lift arm moves slowly or the lift arm rising force is insufficient 913
H-14 When rising, the lift arm comes to move slowly at specific height 914
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises above the ground) 914
H-16 Hydraulic drifts of the lift arm occur often 914
H-17 The lift arm wobbles during operation 914
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily 915
H-19 The bucket does not tilt back 916
H-20 The bucket moves slowly or the tilting-back force is insufficient 917
H-21 The bucket comes to operate slowly in the midst of tilting-back 918
H-22 The bucket cylinder cannot hold down the bucket 918
H-23 Hydraulic drifts of the bucket occur often 918
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) 918
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily 919
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy 919
H-27 The ECSS does not operate and machine pitches and bounces 920
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 921
600 Troubleshooting of engine (S-mode) 923
Method of using troubleshooting charts 924
S-1 Starting performance is poor 928
S-2 Engine does not start 929
S-3 Engine does not pick up smoothly 932
S-4 Engine stops during operations 933
S-5 Engine does not rotate smoothly 934
S-6 Engine lacks output (or lacks power) 935
S-7 Exhaust smoke is black (incomplete combustion) 936
S-8 Oil consumption is excessive (or exhaust smoke is blue) 937
S-9 Oil becomes contaminated quickly 938
S-10 Fuel consumption is excessive 939
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 940
S-12 Oil pressure drops 941
S-13 Oil level rises (Entry of coolant or fuel) 942
S-14 Coolant temperature becomes too high (overheating) 943
S-15 Abnormal noise is made 944
S-16 Vibration is excessive 945
50 Disassembly and assembly 947
100 General information on disassembly and assembly 947
Precautions before work 948
How to read this manual 949
Coating materials list 951
Special tools list 954
Sketches of special tools 957
200 Engine and cooling system 965
Removal and installation of fuel supply pump assembly 966
Removal and installation of fuel injector assembly 970
Removal and installation of engine hood assembly 974
Removal and installation of cylinder head assembly 976
Removal and installation of radiator 986
Removal and installation of air aftercooler 989
Removal and installation of hydraulic oil cooler assembly 991
Removal and installation of engine and HST pump and 3-gear pump assembly 993
Removal and installation of engine front oil seal 998
Removal and installation of engine rear oil seal 1001
Removal and installation of cooling fan and fan motor assembly 1004
Removal and installation of fuel tank assembly 1007
300 Power train 1013
Removal and installation of transfer and HST motor assembly 1014
Disassembly and assembly of transfer assembly 1017
Removal and installation of parking brake assembly 1037
Disassembly and assembly of parking brake assembly 1038
Removal and installation of front axle assembly 1042
Removal and installation of rear axle assembly 1044
Disassembly and assembly of axle housing assembly 1046
Disassembly and assembly of differential assembly 1057
400 Undercarriage and frame 1081
Removal and installation of center hinge pin 1082
Removal and installation of counterweight 1090
500 Hydraulic system 1093
Removal and installation of transfer and HST pump and 3-gear pump assembly 1094
Removal and installation of HST motor 1 assembly 1098
Removal and installation of HST motor 2 assembly 1101
Removal and installation of work equipment control valve assembly 1103
Removal and installation of hydraulic tank assembly 1106
Disassembly and assembly of hydraulic cylinder assembly 1108
600 Work equipment 1113
Removal and installation of work equipment assembly 1114
700 Cab and its attachments 1123
Removal and installation of operator’s cab and floor frame assembly 1124
Removal and installation of operator’s cab glass (Stuck glass) 1129
Removal and installation of air conditioner unit 1137
800 Electrical system 1145
Removal and installation of monitor panel 1146
Removal and installation of engine controller assembly 1148
Removal and installation of HST controller assembly 1150
Removal and installation of KOMTRAX terminal assembly (If equipped) 1151
80 Appendix 1153
100 Air conditioner 1153
Precautions before work 1155
Air conditioner component 1156
Configuration and function of refrigerating cycle 1158
Outline of refrigerating cycle 1159
Air conditioner unit 1162
Functions of major components in the air conditioner unit 1163
Blower and intake unit 1164
Compressor 1165
Condenser 1166
Receiver drier 1167
Air conditioner control panel 1168
Caution about refrigerant 1170
Troubleshooting procedure 1171
Block diagram and circuit diagram of control system 1172
Detail of air conditioner unit 1175
Arrangement of connector pins 1176
Part and connector locations 1177
Testing with self-diagnosis function (indication on control panel) 1179
Testing temperature control 1180
Testing Recirc/Fresh changeover 1181
Testing evaporator temperature sensor electrically 1183
Testing relays 1184
Troubleshooting chart 1 1185
Troubleshooting chart 2 1186
Troubleshooting for electrical system (E mode) 1189
Troubleshooting with gauge pressure 1204
Connection of service tool 1206
Precautions for connecting air conditioner piping 1207
Handling of compressor oil 1208
90 Diagrams and drawings 1211
100 Hydraulic diagrams and drawings 1211
Hydraulic circuit diagram 1213
200 Electrical diagrams and drawings 1217
Common electrical circuit diagram 1219
Connector list and stereogram 1243

DESCRIPTION:

Komatsu WA150-6 Wheel Loader Shop Manual SEN04885-11 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
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 instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by 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.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 29/12/24