Komatsu WA150PZ-5 Wheel Loader Shop Manual VEBM420100 PDF

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Komatsu WA150PZ-5 Wheel Loader Shop Manual VEBM420100 – PDF DOWNLOAD

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Komatsu WA150PZ-5 Wheel Loader Shop Manual VEBM420100 – PDF DOWNLOAD 

Language : English
Pages : 772
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA150PZ-5 Wheel Loader Shop Manual VEBM420100 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
WA150PZ-5               H50051 and up

VEBM420100_150PZ_SHOP_MANUAL 1
01 GENERAL 3
GENERAL ASSEMBLY DRAWINGS 4
SPECIFICATIONS 5
WEIGHT TABLE 9
LIST OF LUBRICANT AND COOLANT 11
10 STRUCTURE AND FUNCTION 13
Damper 15
Engine mount and transfer mount 14
Cooling system 16
Power train 17
Power train system diagram 18
Drive shaft 20
HST hydraulic piping diagram 21
HST pump 22
High-pressure relief valve 24
Low-pressure relief valve 26
HST charge pump 27
Speed-related valve (DA valve) 28
High-pressure cut-off valve 29
HST motor 30
EP servo valve 33
HA servo valve 34
Forward-reverse shuttle valve 35
Transfer 36
Clutch solenoid valve 47
Axle 48
Differential 50
Limited-slip differential 56
Final drive 60
Axle mounting and center hinge pin 62
Steering piping 67
Steering column 68
Priority valve 69
Orbit-roll valve 72
Steering cylinder 80
Emergency steering piping 82
Emergency steering valve 83
Brake piping 86
Brake valve 87
Inching valve 91
Charge valve 92
Accumulator (for brake) 96
Slack adjuster 97
Brake 100
Parking brake control 103
Parking brake 104
Hydraulic piping 106
Work equipment lever linkage 108
Hydraulic tank 109
3-gear pump unit 112
Accumulator (for ppc circuit) 114
Lock valve 115
Accumulator (for E C S S ) 120
E C S S valve 118
Hydraulic piping of coolingsystem 121
Cooling fan motor 122
Work equipment linkage 144
Bucket 146
Bucket positioner and boom kick-out 147
Work equipment cylinder 153
Air conditioner 154
Machine monitoring system 155
Machine monitor 165
List of items displayed onmonitor 166
Electrical system (HSTcontroller system) 192
HST controller 196
Engine start circuit 197
Engine stop circuit 199
Preheating circuit 200
Parking brake circuit 201
Electronically controlled suspension system 204
Sensors 205
Work equipment control valve 124
Work equipment PPC valve 137
STANDARD VALUE TABLE FOR ENGINE 212
STANDARD VALUE TABLE FOR CHASSIS 213
20 TESTING AND ADJUSTING 211
Tools for testing, adjusting, and troubleshooting 220
Measuring engine speed 222
Special tools required 222
MEASURING HIGH-IDLING AND LOW-IDLING SPEEDS 222
MEASURING HST STALL SPEED 223
MEASURING HYDRAULIC SPEED 223
MEASURING FULL STALL SPEED 223
Measuring exhaust gas color 224
Special tools required 224
Adjusting valve clearance 225
Special tools required 225
Measuring compression pressure 227
Special tools required 227
Measuring blow-by pressure 228
Special tools required 228
Testing and adjusting fuel injection timing 229
Special tools required 229
Measuring engine oil pressure 230
Special tools required 230
Measuring, testing operating force of accelerator pedal 231
Special tools required 231
MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL 231
OPERATING ANGLE OF ACCELERATOR PEDAL 232
Adjusting engine stop solenoid 233
Adjusting engine speed sensor 234
Testing and adjusting air conditioner compressor belt tension 234
Testing 234
Adjusting 234
Measuring directional lever 235
Special tools required 235
Operating effort of directional lever 235
Travel of directional lever 235
Testing and adjusting HST oil pressure 236
Special tools required 236
Adjusting 239
Measuring clutch control pressure 241
Special tools required 241
Testing and adjusting steering wheel 242
Special tools required 242
MEASURING PLAY OF STEERING WHEEL 242
Method of measurement 242
MEASURING OPERATING FORCE OF STEERING WHEEL 243
Measurement method 243
MEASURING OPERATING TIME FOR STEERING WHEEL 243
Measurement method 243
Testing and adjusting steering oil pressure 244
Special tools required 244
Method of measuring main relief pressure 244
Method of adjusting main relief pressure 245
Bleeding air from steering circuit 246
Testing hydraulic fan 247
Special tools required 247
Measuring fan speed 247
Measuring oil pressure 247
Measuring brake pedal 248
Operating effort of pedal 248
Testing and adjusting brake pedal linkage 249
Testing 249
Adjusting 249
Measuring brake performance 250
Measurement method 250
Testing and adjusting accumulator charge pressure 251
Special tools required 251
Measuring 251
Adjusting 251
Measuring brake oil pressure 252
Special tools required 252
Measuring 252
Brake test tool 253
Measuring wear of brake disc 254
Special tool required 254
Bleeding air from brake circuit 255
Special tools required 255
Measuring parking brake performance 256
Measurement method 256
Testing and adjusting parking brake control cable 257
Special tool required 257
Testing 257
Adjusting 257
Measuring and adjusting work equipment control lever 258
Special tools required 258
Measurement 258
Testing and adjusting work equipment hydraulic pressure 259
Special tools required 259
Measuring condition 259
Measuring 259
Adjusting 259
Testing and adjusting work equipment PPC oil pressure 260
Special tools required 260
Measuring condition 260
Measuring 260
Bleeding air 262
Special tools required 262
Releasing remaining pressure in hydraulic circuit 263
Testing and adjusting bucket positioner 264
Testing 264
Adjusting 264
Testing and adjusting of boom kick-out 265
Testing 265
Adjusting 265
Checking proximity switch actuation display lamp 266
Proximity switch actuation display lamp (red) 266
Procedure for checking diode 267
Method of connecting T-adapter for HST controller 268
Special functions of machine monitor 269
Flow of modes and functions 270
Operator mode 273
Service mode 1 273
Service mode 2 273
Character display 273
Operating switches 273
Operator mode operation and displays 273
Error code table 278
Procedure for switching to Service Mode 1 and screen display 280
Real-time monitoring items 285
Table of filter and oil replacement interval set items (when sipping) 286
Service mode 2 287
Pm clinic inspection chart 288
WA150-5H H50051 and up 288
TESTING AND ADJUSTING 219
Points to remember when troubleshooting 292
Sequence of events in troubleshooting 293
Precautions when carrying out maintenance 294
Check before troubleshooting 302
Categories, procedure, and method of using troubleshooting charts 303
Phenomena considered to be failures and troubleshooting no 304
Connection table for connector pin numbers 308
T-adapter table 329
Connector types and mounting locations 333
Connector layout drawing 340
TROUBLESHOOTING 291
HST controller system diagram 346
Before troubleshooting code display 348
ERROR CODE AND POSSIBLE CAUSES TABLE 348
Before troubleshooting electrical system 349
FUSE BOX CONNECTION TABLE 349
Information contained in troubuleshooting table 350
Related circuit diagram 351
Phenomena code table 351
Error Code [989F00] (HST motor protection caution (00)) 352
Error Code [DHH1KX] (HST oil pressure sensor input signal outside range (KX)) 353
Related circuit diagram 354
Error Code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch (LC)) 355
Related circuit diagram 355
Error Code [DW26KZ] (Motor 2 solenoid system discontinuity or short-circuiting (KZ)) 356
Related circuit diagram 357
Error Code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ)) 358
Related circuit diagram 359
Error Code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ)) 360
Related circuit diagram 361
Troubleshooting Code [HST-1] (Defective HST controller power source (HST controller does not func 362
Related circuit diagram 363
Troubleshooting Code [HST-2] (Travel speed does not shifted) 364
Related circuit diagram 366
Troubleshooting Code [HST-3] HST Output Control (Traction control) cannot be controlled 367
Related circuit diagram 368
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE) 345
HST-4 Travel speed limit cannot be changed when gear speed selector switch is in “1st” position 369
Related circuit diagram 371
HST-5 Travel speed is not increased 372
Related circuit diagram 374
Related electrical circuit diagram 376
Related circuit diagram 376
TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE) 375
ECSS-1 Malfunction of travel damper 377
Specification of load meter (STD) 377
Malfunction of travel damper 377
a) Travel damper does not operate 377
b) Travel damper is not reset 380
Monitor system circuit diagram 384
Before troubleshooting code display 388
ERROR CODE AND POSSIBLE CAUSES TABLE 388
Before troubleshooting electrical system 389
FUSE BOX CONNECTION TABLE 389
Information contained in troubuleshooting table 390
Related circuit diagram 391
Phenomena code table 391
Error Code [15B0NX] 392
(HST oil filter clogged (NX)) 392
Related circuit diagram 392
Error Code [2G42ZG] 393
(Decreased brake oil pressure (ZG)) 393
Related circuit diagram 393
Error Code [989F00] 394
(HST motor protection caution (00)) 394
Error Code [989FN1] 395
(HST overrunning (N1)) 395
Error Code [AB00L6] 396
(Defective battery charging circuit (L6)) 396
Related circuit diagram 396
Error Code [AB00MA] 397
(Defective battery charging circuit (MA)) 397
Related circuit diagram 397
Error Code [B@BAZG] 398
(Degreased engine oil pressure (ZG)) 398
Related circuit diagram 398
Error Code [B@BCNS] 399
(Engine water temperature overheating (NS)) 399
Related circuit diagram 399
Error Code [B@BCZK] 400
(Alarm indicating low coolant level (ZK)) 400
Related circuit diagram 400
Error Code [B@C7NS] 401
(Axle oil temperature overheating (NS)) 401
Related circuit diagram 401
Error Code [B@CRNS] 402
(HST oil temperature overheating (NS)) 402
Related circuit diagram 402
Error Code [D5ZHL6] 404
(Starting switch “C” (IGN “C”) input failure (L6)) 404
Related circuit diagram 405
Error Code [DAF0KT] 406
(Controller inside failure (KT)) 406
Error Code [DAJ0KR] 408
(HST controller communication failure (KR)) 408
Related circuit diagram 409
Error Code [DD15LD] 410
(Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD)) 410
Related circuit diagram 410
Error Code [DD16LD] 411
(Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD)) 411
Related circuit diagram 411
Error Code [DD17LD] 412
(Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD)) 412
Related circuit diagram 412
Error Code [DD18LD] 413
(Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD)) 413
Related circuit diagram 413
Error Code [DDK3KB] 414
(Multiple directional lever FR signal input (KB)) 414
Related circuit diagram 415
Error Code [DDS5L6] 416
(Decreased steering oil pressure (L6)) 416
Related circuit diagram 416
Error Code [DGE2KX] 417
(Engine coolant temperature (High temperature) sensor system failure (KX)) 417
Related circuit diagram 417
Error Code [DGE3L6] 419
(Engine coolant temperature (Low temperature) sensor system failure (L6)) 419
Related circuit diagram 419
Error Code [DGH1KX] 420
(HST oil temperature sensor system failure (KX)) 420
Related circuit diagram 420
Error Code [DGR4KA] 421
(Axle oil temperature sensor system discontinuity (KA)) 421
Related circuit diagram 421
Error Code [DGR4KX] 422
(Axle oil temperature sensor system failure (KX)) 422
Related circuit diagram 422
Error Code [DHE4L6] 423
(Engine oil pressure sensor system discontinuity (L6)) 423
Related circuit diagram 423
Troubleshooting Code [MON-1] 425
(The parking brake indicator lamp does not light ON) 425
Related circuit diagram 427
Related circuit diagram 428
Troubleshooting Code [MON-2] 429
(The brake oil pressure caution lamp does not light ON) 429
Related circuit diagram 429
Troubleshooting Code [MON-3] 430
(The engine water temperature caution lamp does not light ON, or after the engine starts, the eng 430
Related circuit diagram 430
Troubleshooting Code [MON-4] 431
(The HST oil temperature caution lamp does not light ON, or after the engine starts, the HST oil 431
Related circuit diagram 431
Troubleshooting Code [MON-5] 432
(The fuel level gauge does not rise or decrease ) 432
Related circuit diagram 432
Troubleshooting Code [MON-6] 433
(The radiator coolant level caution lamp does not light ON) 433
Related circuit diagram 433
Troubleshooting Code [MON-7] 434
(The steering oil pressure caution lamp does not light ON) 434
Related circuit diagram 434
Troubleshooting Code [MON-8] 435
(The emergency steering oil pressure indicator lamp does not light ON) 435
Related circuit diagram 435
Troubleshooting Code [MON-9] 436
(Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1)) 436
Related circuit diagram 436
Troubleshooting Code [MON-10] 438
(Input failure in monitor panel mode selector switch 1 [U] (Panel switch 2)) 438
Related circuit diagram 439
Troubleshooting Code [MON-11] 440
(Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3)) 440
Related circuit diagram 441
Troubleshooting Code [MON-12] 442
(Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4)) 442
Related circuit diagram 443
Troubleshooting Code [MON-13] 444
(The alarm buzzer does not sound or stop) 444
Related circuit diagram 445
Troubleshooting Code [MON-14] 446
The wiper does not function 446
Troubleshooting Code [MON-15] 446
The lamps do not work properly 446
TROUBLESHOOTING OF monitor SYSTEM (mon MODE) 383
Electrical system diagram 448
Parking brake related diagram 452
Before troubleshooting electrical system 454
Fuse box connection table 454
Information contained in troubuleshooting table 456
Related circuit diagram 457
Troubleshooting Code [E-1] 458
(The engine does not start) 458
a) Defective starting motor system 458
Related circuit diagram 461
Troubleshooting Code [E-2] 464
(The engine does not stop) 464
Related circuit diagram 465
Troubleshooting Code [E-3] 466
(Preheating is impossible or constant) 466
a) Preheating is impossible 466
b) Preheating is constant 471
Troubleshooting Code [E-4] 474
(The parking brake (Mechanical type) does not function) 474
a) Parking brake dragging prevention does not function (mechanical type) 474
b) Parking brake “non-applied” indicator does not light up (mechanical type) 476
Troubleshooting Code [E-5] 478
(Defective boom kick-out function and cancellation) 478
Related circuit diagram 480
Troubleshooting Code [E-6] 481
(Defective bucket positioner function and cancellation) 481
Related circuit diagram 483
Troubleshooting Code [E-7] 491
(Defective lift arm FLOATING holding function and cancellation) 491
Related circuit diagram 492
Troubleshooting Code [E-9] 493
(The wiper does not function) 493
a) The rear wiper does not function 493
Related circuit diagram 495
b) The rear wiper does not function 496
Related circuit diagram 497
Troubleshooting Code [E-10] 498
(The window washer does not function) 498
Related circuit diagram 500
Troubleshooting Code [E-11] 501
(Lamps do not work properly) 501
a) Neither high beam nor low beam of headlamp light up 501
Related circuit diagram 503
b) Head lamp (Lo beam) does not light ON 504
Related circuit diagram 504
c) Head lamp (Hi beam) does not light ON 505
Related circuit diagram 505
d) Clearance lamp (Small lamp) does not light ON 506
Related circuit diagram 507
e) Turn signal lamp does not blink 508
Related circuit diagram 509
f) Working lamp does not light ON 510
Related circuit diagram 511
Troubleshooting Code [E-12] 512
(The horn does not sound) 512
Related circuit diagram 513
Troubleshooting Code [E-13] 517
(Defective of the air conditioner) 517
a) The air conditioner does not work 517
Related circuit diagram 518
c) Does not cool or temperature cannot be adjusted 519
Related circuit diagram 521
d) Impossible to switch between recirculated air and fresh air 522
Related circuit diagram 522
e) Impossible to switch vents 522
TROUBLESHOOTING OF ELECTRICAL SYSTEM 447
(E MODE) 447
b) Defective fuel cut solenoid system 462
Related circuit diagram 468
Related circuit diagram 472
Troubleshooting Code [E-8] 484
(Travel direction is not changed normally) 484
a) When directional lever is set in “F”, machine does not travel forward 484
Related circuit diagram 487
b) When directional lever is set in “R”, machine does not travel in reverse 488
b) Air does not flow out or amount of air cannot be adjusted 514
Related circuit diagram 516
f) Defective cooling (Mechanical system) 523
Related circuit diagram 523
g) Defective heating (Defective hot-water circuit) 524
h) Abnormal sound comes out 525
i) Water leaks 526
Method of using troubleshooting chart 528
Error code and cause table 530
H-1 532
The machine does not start 532
H-2 533
The travel speed is slow 533
H-3 534
The thrusting force is weak 534
H-4 535
Engine stalls when traveling or engine speed drops excessively 535
H-5 536
The gear is not shifted 536
H-6 537
The steering wheel does not turn 537
H-7 538
The steering wheel is heavy 538
H-8 539
Steering wheel shakes or jerks 539
H-9 539
Machine deviates naturally to one side when traveling 539
H-10 540
The brake does not work or does not work well 540
H-11 541
The brake is not released or is dragged 541
H-12 542
The lift arm does not rise or lower 542
H-13 543
The lift arm moves slowly or the lift arm rising force is insufficient 543
H-14 544
When rising, the lift arm comes to move slowly at specific height 544
H-15 544
The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) 544
H-16 544
Hydraulic drifts of the lift arm occur often 544
H-17 544
The lift arm wobbles during operation 544
H-18 545
When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily 545
H-19 546
The bucket does not tilt back 546
H-20 547
The bucket moves slowly or the tilting-back force is insufficient 547
H-21 548
The bucket comes to operate slowly in he midst of tilting-back 548
H-22 548
The bucket cylinder cannot hold down the bucket 548
H-23 548
Hydraulic drifts of the bucket occur often 548
H-24 549
The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) 549
H-25 549
When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily 549
H-26 549
The control levers of the lift arm and bucket do not move smoothly and heavy 549
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 527
H-27 550
The travel damper does not operate and machine pitches and bounces 550
Method of using troubleshooting charts 552
S-7 Exhaust gas is black (incomplete combustion) 554
S-1 556
Starting performance is poor (Starting always takes time) 556
S-2 558
Engine does not start 558
(1) Engine does not turn 558
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) 559
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) 560
S-3 561
Engine does not pick up smoothly (Follow-up is poor) 561
S-4 562
Engine stops during operations 562
S-5 563
Engine does not rotate smoothly (Hunting) 563
S-6 564
Engine lacks output (or lacks power) 564
S-7 565
Exhaust smoke is black (Incomplete combustion) 565
S-8 566
Oil consumption is excessive (or exhaust smoke is blue) 566
S-9 567
Oil becomes contaminated quickly 567
S-10 568
Fuel consumption is excessive 568
S-11 569
Oil is in cooling water, or water spurts back, or water level goes down 569
S-12 570
Oil pressure caution lamp lights up (Drop in oil pressure) 570
S-13 571
Oil level rises (Water, fuel in oil) 571
S-14 572
Water temperature becomes too high (Overheating) 572
S-15 573
Abnormal noise is made 573
S-16 574
Vibration is excessive 574
TROUBLESHOOTING OF ENGINE (S MODE) 551
30 DISASSEMBLY AND ASSEMBLY 575
HOW TO READ THIS MANUAL 576
PRECAUTIONS WHEN PERFORMING OPERATION 578
SPECIAL TOOL LIST 580
SKETCHES OF SPECIAL TOOLS 583
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 590
REMOVAL AND INSTALLATION OF NOZZLE HOLDER 594
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 596
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 603
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 611
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER 613
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 614
REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY 615
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY 617
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY 619
DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY 621
REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY 641
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY 642
REMOVAL AND INSTALLATION OF FRONT AXEL ASSEMBLY 648
REMOVAL AND INSTALLATION OF REAR AXEL ASSEMBLY 650
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY 653
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY 664
REMOVAL AND INSTALLATION OF HST PUMP AND 3-GEAR PUMP ASSEMBLY 687
REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY 690
REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY 692
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY 694
REMOVAL AND INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY 697
REMOVAL AND INSTALLATION OF HYDRAULIC TANK 698
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 700
DISASSMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 706
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY 712
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) 716
REMOVAL AND INSTALLATION OF CENTER HINGE PIN 725
REMOVAL AND INSTALLATION OF COUNTERWEIGHT 733
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 734
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY 736
REMOVAL AND INSTALLATION OF MONITOR PANEL 737
90 OTHERS 741
Hydraulic circuit diagram 743
Electrical circuit diagram 1/4 (1/4) 745
Electrical circuit diagram 1/4 (2/4) 747
Electrical circuit diagram 1/4 (3/4) 749
Electrical circuit diagram 3/4 755
Electrical circuit diagram 4/4 757
Electrical circuit diagram 1/4 (1/4) 759
Electrical circuit diagram 1/4 (2/4) 761
Electrical circuit diagram 1/4 (3/4) 763
Electrical circuit diagram 1/4 (4/4) 765
Electrical circuit diagram 2/4 767
Electrical circuit diagram 3/4 769
Electrical circuit diagram 4/4 771
Electrical circuit diagram 1/4 (4/4) 751

S.V 26/12/24