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KOMATSU WA500-3 SHOP MANUAL SEBM009015 – PDF DOWNLOAD
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Description
KOMATSU WA500-3 SHOP MANUAL SEBM009015 – PDF DOWNLOAD
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KOMATSU WA500-3 SHOP MANUAL SEBM009015 – PDF DOWNLOAD
Language : English
Pages : 1370
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA500-3 SHOP MANUAL SEBM009015 – PDF DOWNLOAD
COVER................................................................................................................................................................. 1 CONTENTS.............................................................................................................................................................. 2 01 GENERAL............................................................................................................................................................ 29 GENERAL ASSEMBLY DRAWING.......................................................................................................................................... 30 SPECIFICATIONS.................................................................................................................................................... 33 WEIGHT TABLE...................................................................................................................................................... 36 LIST OF LUBRICANT AND WATER....................................................................................................................................... 37 10 STRUCTURE AND FUNCTION............................................................................................................................................. 41 GENERAL........................................................................................................................................................... 42 RADIATOR AND OIL COOLER........................................................................................................................................... 44 DAMPER............................................................................................................................................................ 49 TORQUE CONVERTER AND TRANSMISSION PIPING.......................................................................................................................... 51 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................................................................. 54 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN......................................................................................................................... 55 TORQUE CONVERTER AND PTO.......................................................................................................................................... 56 TRANSMISSION...................................................................................................................................................... 58 TRANSMISSION CONTROL VALVE........................................................................................................................................ 72 ECMV (ELECTRONIC CONTROL MODULATION VALVE)........................................................................................................................ 74 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE........................................................................................................................ 80 LUBRICATING RELIEF VALVE.......................................................................................................................................... 82 TORQUE CONVERTER OIL FILTER....................................................................................................................................... 83 PILOT FILTER...................................................................................................................................................... 84 TRANSFER.......................................................................................................................................................... 85 DRIVE SHAFT....................................................................................................................................................... 86 CENTER SUPPORT.................................................................................................................................................... 87 AXLE.............................................................................................................................................................. 88 DIFFERENTIAL...................................................................................................................................................... 90 LIMITED SLIP DIFFERENTIAL......................................................................................................................................... 93 FINAL DRIVE....................................................................................................................................................... 98 AXLE MOUNT........................................................................................................................................................ 100 CENTER HINGE PIN.................................................................................................................................................. 102 STEERING PIPING................................................................................................................................................... 103 STEERING COLUMN................................................................................................................................................... 104 STEERING VALVE.................................................................................................................................................... 105 ORBIT-ROLL VALVE.................................................................................................................................................. 119 STOP VALVE........................................................................................................................................................ 123 DIVERTER VALVE.................................................................................................................................................... 124 BRAKE PIPING...................................................................................................................................................... 127 BRAKE CIRCUIT DIAGRAM............................................................................................................................................. 130 BRAKE VALVE....................................................................................................................................................... 133 CHARGE VALVE...................................................................................................................................................... 138 ACCUMULATOR (FOR BRAKE)........................................................................................................................................... 142 SLACK ADJUSTER.................................................................................................................................................... 143 BRAKE............................................................................................................................................................. 146 PARKING BRAKE CONTROL............................................................................................................................................. 148 PARKING BRAKE..................................................................................................................................................... 149 PARKING BRAKE SOLENOID VALVE...................................................................................................................................... 150 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.................................................................................................................... 151 HYDRAULIC PIPING.................................................................................................................................................. 152 HYDRAULIC CIRCUIT SYSTEM.......................................................................................................................................... 154 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................................... 156 WORK EQUIPMENT LEVER LINKAGE...................................................................................................................................... 158 HYDRAULIC TANK.................................................................................................................................................... 159 ACCUMULATOR (FOR PPC VALVE)....................................................................................................................................... 162 PPC VALVE......................................................................................................................................................... 164 PPC RELIEF VALVE.................................................................................................................................................. 171 CUT-OFF VALVE..................................................................................................................................................... 172 E.C.S.S. CONTROL VALVE............................................................................................................................................ 176 MAIN CONTROL VALVE................................................................................................................................................ 178 WORK EQUIPMENT LINKAGE............................................................................................................................................ 192 BUCKET............................................................................................................................................................ 194 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................................................................... 195 OPERATION OF PROXIMITY SWITCH..................................................................................................................................... 199 CAB............................................................................................................................................................... 203 ROPS CANOPY....................................................................................................................................................... 206 AIR CONDITIONER................................................................................................................................................... 209 ELECTRIC CIRCUIT DIAGRAM.......................................................................................................................................... 214 MACHINE MONITOR SYSTEM............................................................................................................................................ 222 MAIN MONITOR...................................................................................................................................................... 225 MAINTENANCE MONITOR............................................................................................................................................... 230 ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM........................................................................................................ 233 JOYSTICK TRANSMISSION SYSTEM...................................................................................................................................... 243 E.C.S.S. (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)............................................................................................................ 244 TRANSMISSION AND E.C.S.S. CONTROLLER.............................................................................................................................. 252 WORK EQUIPMENT CONTROL SYSTEM..................................................................................................................................... 254 REMOTE POSITION, JOYSTICK STEERING CONTROLLER..................................................................................................................... 259 SENSORS........................................................................................................................................................... 260 ENGINE STARTING CIRCUIT........................................................................................................................................... 265 ENGINE STOP CIRCUIT............................................................................................................................................... 267 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM).................................................................................................................. 269 ELECTRIC TRANSMISSION CONTROL..................................................................................................................................... 272 KICK-DOWN, HOLD SWITCH............................................................................................................................................ 275 KICK-DOWN ELECTRICAL CIRCUIT DIAGRAM.............................................................................................................................. 276 ELECTRIC PARKING BRAKE CONTROL.................................................................................................................................... 279 20 TESTING AND ADJUSTING.............................................................................................................................................. 291 STANDARD VALUE TABLE FOR ENGINE................................................................................................................................... 292 STANDARD VALUE TABLE FOR CHASSIS.................................................................................................................................. 294 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS................................................................................................................. 304 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................................ 329 SKETCHES OF SPECIAL TOOLS......................................................................................................................................... 332 MEASURING ENGINE SPEED............................................................................................................................................ 333 MEASURING EXHAUST GAS COLOR....................................................................................................................................... 335 ADJUSTING VALVE CLEARANCE......................................................................................................................................... 336 MEASURING COMPRESSION PRESSURE.................................................................................................................................... 338 MEASURING BLOW-BY PRESSURE........................................................................................................................................ 341 MEASURING ENGINE OIL PRESSURE..................................................................................................................................... 342 HANDLING EQUIPMENT IN FUEL SYSTEM................................................................................................................................. 344 RELEASING REMAINING PRESSURE IN FUEL SYSTEM....................................................................................................................... 344 CHECK FOR LEAKAGE IN FUEL SYSTEM.................................................................................................................................. 345 BLEEDING AIR FROM FUEL SYSTEM..................................................................................................................................... 346 MEASURING FUEL PRESSURE........................................................................................................................................... 348 TESTING AND ADJUSTING FUEL INJECTION TIMING....................................................................................................................... 349 REDUCED CYLINDER MODE OPERATION................................................................................................................................... 350 METHOD OF REDUCED CYLINDER MODE OPERATION......................................................................................................................... 351 TESTING AND ADJUSTING ALTERNATOR BELT TENSION..................................................................................................................... 353 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................................................ 354 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR................................................................................................. 355 MEASURING EXHAUST TEMPERATURE..................................................................................................................................... 357 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).................................................................................................................... 359 ADJUSTING SPEED SENSOR............................................................................................................................................ 361 ADJUSTING FUEL CONTROL CABLE...................................................................................................................................... 363 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE...................................................................................................................... 364 TESTING AND ADJUSTING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE................................................................................................. 366 PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT........................................................................................... 369 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS........................................................................................................ 370 TESTING AND ADJUSTING STEERING OIL PRESSURE....................................................................................................................... 372 TESTING AND ADJUSTING STEERING STOP VALVE......................................................................................................................... 374 TESTING BRAKE OIL PRESSURE........................................................................................................................................ 375 MEASURING BRAKE DISC WEAR......................................................................................................................................... 376 MEASURING BRAKE PERFORMANCE....................................................................................................................................... 377 MEASURING PARKING BRAKE OIL PRESSURE.............................................................................................................................. 378 TESTING WEAR OF PARKING BRAKE DISC................................................................................................................................ 380 MANUAL RELEASE METHOD FOR PARKING BRAKE........................................................................................................................... 381 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................................................................................................................. 382 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS............................................................. 384 TESTING AND ADJUSTING PPC OIL PRESSURE............................................................................................................................ 396 ADJUSTING PPC VALVE LINKAGE....................................................................................................................................... 400 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....................................................................................................................... 401 ADJUSTING WORK EQUIPMENT LEVER LINKAGE............................................................................................................................ 403 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT................................................................................................................... 404 INITIAL TEACHING METHOD FOR TRANSMISSION CONTROLLER............................................................................................................... 405 TESTING AND ADJUSTING OF BUCKET POSITIONER........................................................................................................................ 407 TESTING AND ADJUSTING OF BOOM KICK-OUT............................................................................................................................ 409 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)....................................................................................................................... 411 BLEEDING AIR...................................................................................................................................................... 413 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................................................................................. 414 TROUBLESHOOTING................................................................................................................................................... 415 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................................................... 416 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................................................... 417 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.............................................................................................................. 418 CHECKS BEFORE TROUBLESHOOTING................................................................................................................................. 426 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................................................ 427 CONNECTOR ARRANGEMENT DIAGRAM................................................................................................................................. 436 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................................................... 438 EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM........................................................................................................ 458 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE............................................................................................................. 478 CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENATION....................................................................................................... 480 TRANSMISSION CONTROLLER LED DISPLAY........................................................................................................................... 490 METHOD OF USING JUDGEMENT TABLE............................................................................................................................... 491 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................................ 492 METHOD OF USING MATRIX TROUBLESHOOTING TABLES................................................................................................................. 494 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (Serial No.: 50001 β 52000)........................................................................................ 497 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................... 498 S-1 Starting performance is poor (Starting always takes time)............................................................................................. 502 S-2 Engine does not start................................................................................................................................. 504 (1) Engine does not turn.............................................................................................................................. 504 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected).......................................................................... 505 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)........................................................................ 506 S-3 Engine does not pick up smoothly (Follow-up is poor).................................................................................................. 507 S-4 Engine stops during operations........................................................................................................................ 508 S-5 Engine does not rotate smoothly (Hunting)............................................................................................................. 509 S-6 Engine lacks output (or lacks power).................................................................................................................. 510 S-7 Exhaust smoke is black (Incomplete combustion)........................................................................................................ 511 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................................................................... 512 S-9 Oil becomes contaminated quickly...................................................................................................................... 513 S-10 Fuel consumption is excessive........................................................................................................................ 514 S-11 Oil is in cooling water, or water spurts back, or water level goes down.............................................................................. 515 S-12 Oil pressure caution lamp lights up (Drop in oil pressure)........................................................................................... 516 S-13 Oil level rises (Water, fuel in oil)................................................................................................................. 517 S-14 Water temperature becomes too high (Overheating)..................................................................................................... 518 S-15 Abnormal noise is made............................................................................................................................... 519 S-16 Vibration is excessive............................................................................................................................... 520 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (Serial No.: 52001 and up)......................................................................................... 521 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................... 523 S-1 Starting performance is poor (starting always takes time)............................................................................................. 526 S-2 Engine does not start................................................................................................................................. 527 a) Engine does not turn............................................................................................................................... 527 b) Engine turns but no exhaust smoke comes out........................................................................................................ 528 c) Exhaust smoke comes out but engine does not start (Fuel is being injected)......................................................................... 529 S-3 Engine does not pick up smoothly (follow-up is poor).................................................................................................. 530 S-4 Engine stops during operations........................................................................................................................ 531 S-5 Engine does not rotate smoothly (hunting)............................................................................................................. 532 S-6 Engine lacks output (or lacks power).................................................................................................................. 533 S-7 Exhaust smoke is black (incomplete combustion)........................................................................................................ 534 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................................................................... 535 S-9 Oil becomes contaminated quickly...................................................................................................................... 536 S-10 Fuel consumption is excessive........................................................................................................................ 537 S-11 Oil is in cooling water (or water spurts back, or water level goes down)............................................................................. 538 S-12 Oil pressure caution lamp lights up (drop in oil pressure)........................................................................................... 539 S-13 Oil level rises (water, fuel in oil)................................................................................................................. 540 S-14 Water temperature becomes too high (overheating)..................................................................................................... 541 S-15 Abnormal noise is made............................................................................................................................... 542 S-16 Vibration is excessive............................................................................................................................... 543 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE).................................................................................................... 545 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS.......................................................................................... 546 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................................................ 548 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM............................................................................................. 556 T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed................................... 560 T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed.......................................... 561 T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed.......................................... 562 T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed........................................ 563 T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed........................................ 564 T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed........................................ 565 T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed........................................ 566 T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed................................................... 567 T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed............................................................ 568 T-10 Failure code [21] (Short circuit, disconnection in range switch system) is displayed................................................................. 572 T-11 Failure code [22] (Disconnection in travel speed sensor system) is displayed......................................................................... 575 T-12 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed.......................................................... 576 T-13 Failure code [24] (Short circuit, disconnection in EEP ROM) is displayed............................................................................. 579 T-14 Failure code [25] (Short circuit in transmission oil temperature system) is displayed................................................................ 580 T-15 Failure code [26] (Short circuit in F ECMV fill switch system) is displayed.......................................................................... 581 T-16 Failure code [27] (Short circuit in R ECMV fill switch system) is displayed.......................................................................... 581 T-17 Failure code [28] (Short circuit in 1st ECMV fill switch system) is displayed........................................................................ 582 T-18 Failure code [29] (Short circuit in 2nd ECMV fill switch system) is displayed........................................................................ 582 T-19 Failure code [30] (Short circuit in 3rd ECMV fill switch system) is displayed........................................................................ 583 T-20 Failure code [31] (Short circuit in 4th ECMV fill switch system) is displayed........................................................................ 583 T-21 Failure code [32] (Short circuit in F or R ECMV fill switch system) is displayed..................................................................... 584 T-22 Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill switch system) is displayed...................................................... 586 T-23 Hold switch system................................................................................................................................... 588 T-24 Kick-down switch system.............................................................................................................................. 588 T-25 Transmission cut-off signal system................................................................................................................... 589 T-26 Neutralizer relay signal system...................................................................................................................... 590 T-27 Buzzer signal system................................................................................................................................. 593 T-28 Network system....................................................................................................................................... 594 T-29 Transmission controller power source system.......................................................................................................... 595 T-30 Short circuit in travel speed sensor system.......................................................................................................... 596 T-31 Disconnection in transmission oil temperature sensor system.......................................................................................... 597 T-32 Disconnection in F ECMV fill switch system........................................................................................................... 598 T-33 Disconnection in R ECMV fill switch system........................................................................................................... 598 T-34 Disconnection in 1st ECMV fill switch system......................................................................................................... 599 T-35 Disconnection in 2nd ECMV fill switch system......................................................................................................... 599 T-36 Disconnection in 3rd ECMV fill switch system......................................................................................................... 600 T-37 Disconnection in 4th ECMV fill switch system......................................................................................................... 600 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)............................................................................................................... 601 TROUBLE DATA DISPLAY...................................................................................................................................... 605 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM..................................................................................................... 612 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM....................................................................................................... 616 ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND HAZARD SYSTEM.............................................................................................. 617 M-1 Main monitor does not work............................................................................................................................ 618 M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up........................................................ 619 M-3 Speedometer display does not work properly............................................................................................................ 622 M-4 Abnormality in shift indicator........................................................................................................................ 623 a) Displays N even when directional lever is at F..................................................................................................... 623 b) Displays N even when directional lever is at R..................................................................................................... 623 c) Does not display N even when directional lever is at N, and displays R when directional lever is at F.............................................. 623 d) Does not display N even when directional lever is at N, and displays F when directional lever is at R.............................................. 624 e) Does not display 1st β 4th......................................................................................................................... 624 M-5 High beam does not light up........................................................................................................................... 625 M-6 Turn signal display does not light up................................................................................................................. 626 a) L.H. turn signal display does not light up......................................................................................................... 626 b) R.H. turn signal display does not light up......................................................................................................... 626 M-7 Abnormality in parking display........................................................................................................................ 627 a) Parking lamp display does not light up............................................................................................................. 627 b) Parking lamp display stays lighted up.............................................................................................................. 627 M-8 Abnormality in preheating system...................................................................................................................... 628 (1) Abnormality in preheating system (QHS)............................................................................................................ 628 a) Does not carry out preheating.................................................................................................................. 628 b) Always carries out preheating for 45 seconds................................................................................................... 629 c) Preheating stays on............................................................................................................................ 629 d) Preheating time becomes shorter, or there is variation......................................................................................... 630 (2) Abnormality in preheating system.................................................................................................................. 631 a) Does not carry out preheating.................................................................................................................. 631 b) Preheating stays on............................................................................................................................ 631 M-9 Night lighting does not light up...................................................................................................................... 633 M-10 Abnormality in front working lamp.................................................................................................................... 634 a) Neither monitor display nor front working lamp light up............................................................................................ 634 b) Working lamp lights up but monitor display does not light up....................................................................................... 634 c) Monitor display lights up but working lamp does not light up....................................................................................... 634 M-11 Abnormality in rear working lamp..................................................................................................................... 636 a) Neither monitor display nor rear working lamp light up............................................................................................. 636 b) Working lamp lights up but monitor display does not light up....................................................................................... 636 c) Monitor display lights up but working lamp does not light up....................................................................................... 636 M-12 Abnormality in transmission cut-off.................................................................................................................. 638 a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change......................... 638 b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off function is actuated when pedal is depressed........ 638 c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated................................... 638 d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF).......................................... 638 e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated............................................ 639 M-13 Abnormality in parking brake dragging warning........................................................................................................ 640 a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when directional lever is at N......................... 640 b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at position other than N.... 640 M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated............................ 644 a) Actuated continuously.............................................................................................................................. 644 b) Not actuated....................................................................................................................................... 644 M-15 Abnormality in buzzer................................................................................................................................ 645 a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)............................................................ 645 b) Buzzer always sounds............................................................................................................................... 645 M-16 Condition of monitor switches is not stored in memory................................................................................................ 646 M-17 Abnormality in failure display mode.................................................................................................................. 648 a) Does not enter failure display mode................................................................................................................ 648 b) Count for time elapsed since failure in failure display mode does not advance...................................................................... 648 M-18 Buzzer is not made to sound by transmission controller............................................................................................... 650 M-19 Abnormality in emergency steering normal display..................................................................................................... 651 a) Emergency steering normal display does not light up................................................................................................ 651 b) Emergency steering normal display stays lighted up................................................................................................. 651 M-20 Abnormality in emergency steering actuation display.................................................................................................. 652 a) Emergency steering actuation display does not light up............................................................................................. 652 b) Emergency steering actuation display stays lighted up.............................................................................................. 652 M-21 Abnormality in auto-greasing system.................................................................................................................. 653 a) Forced greasing cannot be carried out.............................................................................................................. 653 b) Monitor display flashes rapidly (2 times/sec)...................................................................................................... 653 c) When no more grease remains, monitor display flashes rapidly (2 times/sec)......................................................................... 653 d) Monitor display flashes slowly (1 time/sec)........................................................................................................ 654 e) Monitor display goes out........................................................................................................................... 654 M-22 Abnormality in ECSS system........................................................................................................................... 655 a) Display does not change when switch is pressed..................................................................................................... 655 b) Monitor display lights up but ECSS function does not work.......................................................................................... 655 c) Display does not light up.......................................................................................................................... 655 M-23 Failure code is not sent to main monitor (abnormality in network).................................................................................... 656 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)........................................................................................................ 657 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM..................................................................................................... 658 K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does not work.................. 662 a) No lamps on maintenance monitor light up........................................................................................................... 662 b) Some lamps do not light up......................................................................................................................... 663 K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds)................................. 665 K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out...................... 667 K-4 When starting switch is turned ON (engine stopped), CHECK items flash................................................................................. 668 a) Engine oil level display flashes................................................................................................................... 668 b) Engine water level display flashes................................................................................................................. 670 K-5 When starting switch is turned ON (engine started), CAUTION items flash............................................................................... 672 a) Engine oil pressure display flashes................................................................................................................ 672 b) Battery charge level display flashes............................................................................................................... 674 c) Brake oil pressure display flashes................................................................................................................. 676 d) Air cleaner display flashes........................................................................................................................ 677 K-6 CAUTION items are flashing but caution buzzer does not sound.......................................................................................... 679 K-7 There is no abnormality in monitor display but caution buzzer sounds.................................................................................. 680 K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash................................................................. 681 a) CHECK lamp......................................................................................................................................... 681 b) CAUTION lamp....................................................................................................................................... 681 K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up.......................................... 682 a) CHECK lamp......................................................................................................................................... 682 b) CAUTION lamp....................................................................................................................................... 682 K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up).............................. 683 K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up............................................................... 684 K-12 Service meter does not work.......................................................................................................................... 685 K-13 Service meter is running even when engine is stopped................................................................................................. 687 K-14 Abnormality in gauge items........................................................................................................................... 689 a) Abnormality in fuel gauge.......................................................................................................................... 689 b) Abnormality in engine water temperature gauge...................................................................................................... 691 c) Abnormality in torque converter oil temperature gauge.............................................................................................. 693 K-15 Maintenance monitor check............................................................................................................................ 695 a) Check switch system................................................................................................................................ 695 b) Check LED system................................................................................................................................... 695 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................................................................. 697 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTINGγ»STOP AND PREHEATING SYSTEM................................................................... 698 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM....................................................................................................... 701 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM....................................................................................................... 704 ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER SYSTEM................................................................................. 705 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM............................................................................................. 706 E-1 Engine does not start................................................................................................................................. 710 a) Starting motor does not turn....................................................................................................................... 710 b) Starting motor turns............................................................................................................................... 722 E-2 Engine does not stop.................................................................................................................................. 724 E-3 Engine stops when machine is traveling................................................................................................................ 724 E-4 Abnormality in preheating system (QHS)................................................................................................................ 726 a) Does not carry out preheating...................................................................................................................... 726 b) Always carries out preheating for 45 seconds....................................................................................................... 727 c) Preheating stays on................................................................................................................................ 727 d) Preheating time becomes shorter, or there is variation............................................................................................. 728 E-5 Parking brake does not have effect.................................................................................................................... 729 a) Parking brake has no effect when parking brake switch is turned ON (actuated)...................................................................... 729 b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)........................................................... 729 E-6 Parking brake is applied when machine is traveling.................................................................................................... 730 E-7 Parking brake is released when starting switch is turned ON........................................................................................... 734 E-8 Transmission does not change to neutral when parking brake is applied (but parking brake works normally).............................................. 734 E-9 Kick-down switch does not work........................................................................................................................ 738 a) Kick-down switch does not work (shift works correctly during normal gear shift operations)......................................................... 738 b) Kick-down is not canceled.......................................................................................................................... 739 E-10 Boom kick-out cannot be used......................................................................................................................... 740 E-11 Abnormality in bucket positioner function............................................................................................................ 744 E-12 Abnormality in lighting up of front working lamp..................................................................................................... 747 E-13 Abnormality in lighting up of rear working lamp...................................................................................................... 747 E-14 Abnormality in transmission cut-off.................................................................................................................. 747 E-15 Abnormality in parking brake dragging warning........................................................................................................ 747 E-16 Abnormality in buzzer................................................................................................................................ 747 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)................................................................................................... 749 H-1 Machine does not start................................................................................................................................ 750 H-2 Travel speed is slow, thrusting power is weak, lacks power on slopes, does not shift gear............................................................. 754 H-3 Excessive shock when starting machine or shifting gear................................................................................................ 757 H-4 Excessive time lag when starting machine or shifting gear............................................................................................. 759 H-5 Torque converter oil temperature is high.............................................................................................................. 761 H-6 Steering does not turn................................................................................................................................ 762 H-7 Steering does not turn [machine with joystick]........................................................................................................ 763 H-8 Turning, response of steering is poor................................................................................................................. 764 H-9 Turning, response of steering is poor [machine with joystick]......................................................................................... 766 H-10 Steering is heavy.................................................................................................................................... 768 H-11 Joystick is heavy [machine with joystick]............................................................................................................ 768 H-12 Steering wheel shakes or jerks....................................................................................................................... 769 H-13 Steering shakes or there is excessive shock [machine with joystick].................................................................................. 770 H-14 Turning radius is different between left and right at maximum steering............................................................................... 770 H-15 Wheel brakes do not work or braking effect is poor................................................................................................... 772 H-16 Wheel brakes are not released or brakes drag......................................................................................................... 774 H-17 Parking brake does not work or braking effect is poor................................................................................................ 775 H-18 Parking brake is not released or brake drags (including emergency release system).................................................................... 776 H-19 Neither boom nor bucket move......................................................................................................................... 777 H-20 Both boom and bucket are slow or lack power.......................................................................................................... 778 H-21 Boom does not move................................................................................................................................... 779 H-22 Boom does not move [machines with remote boom control]............................................................................................... 780 H-23 Boom is slow or boom lacks power..................................................................................................................... 781 H-24 Boom is slow or boom lacks power [machines with remote boom control]................................................................................. 782 H-25 Boom cannot be set to FLOAT or cannot be released from FLOAT......................................................................................... 783 H-26 Boom drops momentarily when control lever is operated from HOLD to RAISE............................................................................. 783 H-27 Remote boom control does not work [machines with remote boom control]................................................................................ 784 H-28 Excessive hydraulic drift of boom.................................................................................................................... 785 H-29 Bucket does not move................................................................................................................................. 786 H-30 Bucket is slow or lacks power........................................................................................................................ 787 H-31 Excessive hydraulic drift of bucket.................................................................................................................. 788 H-32 ECSS does not work, and there is pitching and bouncing [machines with ECSS].......................................................................... 789 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)................................................................................ 791 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.......................................................................................................... 792 Electrical circuit diagram for ECSS....................................................................................................................... 796 D-1 ECSS does not work.................................................................................................................................... 798 a) Error code [d0] is displayed....................................................................................................................... 800 b) Error code [d1] is displayed....................................................................................................................... 800 c) Error code [d2] is displayed....................................................................................................................... 801 d) Error code [d3] is displayed....................................................................................................................... 801 e) No abnormality display is given.................................................................................................................... 803 D-2 ECSS cannot be canceled............................................................................................................................... 806 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)............................................................................................... 807 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS.............................................................................................. 808 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................................................ 810 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM............................................................................................................ 814 J-1 Failure code [56] (Short circuit, disconnection in caution relay output) is displayed................................................................. 816 J-2 Failure code [57] (Short circuit in steering right solenoid (detected when output)) is displayed...................................................... 818 J-3 Failure code [58] (Short circuit in steering left solenoid (detected when output)) is displayed....................................................... 819 J-4 Failure code [59] (Short circuit in steering right solenoid (HOT end)) is displayed................................................................... 820 J-5 Failure code [60] (Short circuit in steering left solenoid (HOT end)) is displayed.................................................................... 821 J-6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay output) is displayed................................................... 822 J-7 Failure code [62] (Short circuit, disconnection in joystick steering neutral signal) is displayed..................................................... 823 J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever potentiometer system) is displayed......................................... 824 J-9 Abnormality in power source, voltage.................................................................................................................. 825 J-10 Abnormality in joystick steering ON-OFF signal system................................................................................................ 826 J-11 Disconnection in steering right solenoid............................................................................................................. 827 J-12 Disconnection in steering left solenoid.............................................................................................................. 828 TROUBLESHOOTING OF REMOTE BOOM POSITIONER CONTROLLER SYSTEM (W MODE).......................................................................................... 829 JUDGEMENT TABLE FOR REMOTE BOOM POSITIONER CONTROLLER SYSTEM RELATED PARTS................................................................................ 830 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................................................ 832 ELECTRICAL CIRCUIT DIAGRAM FOR REMOTE BOOM POSITIONER SYSTEM.............................................................................................. 834 W-1 Failure code [43] (Short circuit, disconnection in damping solenoid system) is displayed.............................................................. 837 W-2 Failure code [44] (Short circuit in power source at hot end of damping solenoid) is displayed......................................................... 838 W-3 Failure code [45] (Short circuit in power source at return end of damping solenoid) is displayed...................................................... 838 W-4 Failure code [49] (Short circuit, disconnection in boom lever kick-out relay system) is displayed..................................................... 839 W-5 Failure code [51] (Disconnection in boom RAISE, LOWER detection pressure switch) is displayed......................................................... 840 W-6 Failure code [52] (Short circuit, disconnection in boom angle potentiometer system) is displayed...................................................... 841 W-7 Sensor cannot be adjusted............................................................................................................................. 842 W-8 Abnormality in engine speed signal system............................................................................................................. 842 W-9 Remote positioner RAISE, LOWER LEDs do not light up................................................................................................... 845 a) Remote positioner switch system.................................................................................................................... 845 b) Remote positioner LED system....................................................................................................................... 845 W-10 Remote positioner RAISE set LED does not flash....................................................................................................... 846 a) Remote positioner RAISE set switch system.......................................................................................................... 846 b) Remote positioner RAISE set LED system............................................................................................................. 846 W-11 Remote positioner LOWER set LED does not flash....................................................................................................... 847 a) Remote positioner LOWER set switch system.......................................................................................................... 847 b) Remote positioner LOWER set LED system............................................................................................................. 847 W-12 Buzzer for switch operation does not sound........................................................................................................... 848 W-13 Shock when stopping boom (abnormality in boom lever detent switch)................................................................................... 849 W-14 Short circuit in boom RAISE, LOWER pressure detection switch......................................................................................... 850 TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM (C MODE)............................................................................... 851 ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM........................................................................ 854 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM..................................................................................................... 856 C-1 When engine is running, engine oil level display shows βAbnormalβ..................................................................................... 858 C-2 When engine is running, battery electrolyte level display shows βAbnormalβ............................................................................ 859 C-3 Abnormality in engine water level display............................................................................................................. 860 a) Display shows βAbnormalβ........................................................................................................................... 860 b) Display shows βDisconnectionβ...................................................................................................................... 860 c) Display shows βShort circuitβ...................................................................................................................... 860 C-4 Abnormality in brake oil pressure display............................................................................................................. 862 a) When engine is running, display shows βAbnormalβ................................................................................................... 862 b) Display shows βDisconnectionβ...................................................................................................................... 863 c) Display shows βShort circuitβ...................................................................................................................... 863 C-5 Abnormality in engine oil pressure display............................................................................................................ 864 a) When engine is running, display shows βAbnormalβ................................................................................................... 864 b) When engine is stopped or running, display shows βDisconnectionβ................................................................................... 864 c) Only when engine is stopped, display shows βDisconnectionβ......................................................................................... 864 d) Display shows βShort circuitβ...................................................................................................................... 865 C-6 When starting switch is at ON (engine started), battery charge display shows βAbnormalβ............................................................... 866 C-7 When starting switch is at ON (engine started), air cleaner display shows βAbnormalβ.................................................................. 867 C-8 CAUTION item display shows βAbnormalβ, but alarm buzzer does not sound................................................................................ 868 C-9 Monitor display does not show βAbnormalβ, but alarm buzzer sounds..................................................................................... 869 C-10 CAUTION item display shows βAbnormalβ, but warning lamp (CHECK lamp, CAUTION lamp) does not flash.................................................... 870 a) CHECK lamp......................................................................................................................................... 870 b) CAUTION lamp....................................................................................................................................... 870 C-11 Monitor display does not show any abnormality, but warning lamp (CHECK lamp, CAUTION lamp) lights up................................................. 871 a) CHECK lamp......................................................................................................................................... 871 b) CAUTION lamp....................................................................................................................................... 871 C-12 Service meter does not work.......................................................................................................................... 872 C-13 Service meter is running when engine is stopped...................................................................................................... 872 C-14 Abnormality in fuel gauge............................................................................................................................ 873 a) Display shows βDisconnectionβ or low fuel level.................................................................................................... 873 b) Display always shows FULL and does not go down..................................................................................................... 873 C-15 Abnormality in engine water temperature gauge........................................................................................................ 874 a) Display shows βShort circuitβ...................................................................................................................... 874 b) Display always shows lowest level and does not go up............................................................................................... 874 C-16 Abnormality in torque converter oil temperature gauge................................................................................................ 875 a) Display shows βShort circuitβ...................................................................................................................... 875 b) Display always shows lowest level and does not go up............................................................................................... 875 C-17 When starting switch is turned to ON, monitor is not actuated (KOMATSU is not displayed)............................................................. 876 a) Main monitor CHECK lamps do not light up........................................................................................................... 876 b) Main monitor CHECK lamps light up.................................................................................................................. 877 C-18 Does not switch to working memory (engine running) mode, or switches to check before starting mode when engine is running............................ 878 C-19 Abnormality in MDC monitor display................................................................................................................... 879 a) Display color is abnormal.......................................................................................................................... 879 b) Display flickers................................................................................................................................... 879 C-20 Even when switch is operated, nothing functions...................................................................................................... 880 C-21 Does not switch to TV/video mode..................................................................................................................... 882 a) Stays at PARKING BRAKE APPLIED display............................................................................................................. 882 b) Display does not light up.......................................................................................................................... 884 C-22 Abnormality in memory data........................................................................................................................... 886 a) Load meter data is not saved to memory............................................................................................................. 886 b) Maintenance time is not saved to memory............................................................................................................ 886 C-23 Engine speed stays at 0 rpm.......................................................................................................................... 887 C-24 Pressure sensor display shows βDisconnectionβ........................................................................................................ 888 a) Sensor power source display also shows βAbnormalβ.................................................................................................. 888 b) Only pressure sensor display shows βDisconnectionβ................................................................................................. 888 C-25 Load meter cannot weigh load......................................................................................................................... 889 a) Cannot carry out calibration....................................................................................................................... 889 b) Can carry out calibration.......................................................................................................................... 890 C-26 Abnormality in lever switch.......................................................................................................................... 891 a) Sub-total switch does not work..................................................................................................................... 891 b) Cancel switch does not work........................................................................................................................ 891 C-27 Printer does not print out........................................................................................................................... 892 C-28 Abnormality in antenna system........................................................................................................................ 893 C-29 Abnormality in speaker system........................................................................................................................ 894 a) Abnormality in right speaker....................................................................................................................... 894 b) Abnormality in left speaker........................................................................................................................ 894 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)........................................................................................................ 895 TABLE OF ERROR CODES...................................................................................................................................... 897 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED.......................................................................... 898 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................... 906 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM................................................................................................... 910 ENG-1 Error code E-1b [Abnormality in Ne speed sensor system]............................................................................................. 913 ENG-2 Error code E-1c [Abnormality in G speed sensor system].............................................................................................. 914 ENG-3 Error code E-22 [Overrun]........................................................................................................................... 915 ENG-4 Error code E-31 [Abnormality in throttle sensor system]............................................................................................. 916 ENG-5 Error code E-3c [Abnormality in boost pressure sensor system]....................................................................................... 918 ENG-6 Error code E-3d [Abnormality in fuel temperature sensor system]..................................................................................... 921 ENG-7 Error code E-51 [Abnormality in preheater relay coil system]........................................................................................ 922 ENG-8 Error code E-54 [Short circuit in starting switch C signal system].................................................................................. 923 ENG-9 Error code E-56 [Abnormality in power supply system 1].............................................................................................. 924 ENG-10 Error code E-57 [Abnormality in power supply system 2]............................................................................................. 925 ENG-11 Error code E-5A [Abnormality in Q adjustment switch signal]........................................................................................ 926 ENG-12 Error code E-6A [Abnormality in low water temperature sensor system]............................................................................... 927 ENG-13 Error code E-70 [Overcurrent in fuel supply pump PCV1 system]...................................................................................... 928 ENG-14 Error code E-71 [Overcurrent in fuel supply pump PCV2 system]...................................................................................... 929 ENG-15 Error code E-74 [Disconnection in fuel supply pump PCV1 system].................................................................................... 930 ENG-16 Error code E-75 [Disconnection in fuel supply pump PCV2 system].................................................................................... 931 ENG-17 Error code E-77 [Abnormality in common rail fuel pressure sensor system]........................................................................... 932 ENG-18 Error code E-79 [Abnormality in high common rail fuel pressure 1]γError code E-7A [Abnormality in high common rail fuel pressure 2]................ 936 ENG-19 Error code E-7b [No-pressure feed by fuel supply pump 1]γError code E-7c [No-pressure feed by fuel supply pump 2].................................. 938 ENG-20 Error code E-7d [Abnormality in common rail high fuel pressure].................................................................................... 941 ENG-21 Error code E-80 [Defective controller]............................................................................................................. 942 ENG-22 Error code E-81 [Disconnection in No. 1 fuel injector system]...................................................................................... 943 ENG-23 Error code E-82 [Disconnection in No. 2 fuel injector system]...................................................................................... 944 ENG-24 Error code E-83 [Disconnection in No. 3 fuel injector system]...................................................................................... 945 ENG-25 Error code E-84 [Disconnection in No. 4 fuel injector system]...................................................................................... 946 ENG-26 Error code E-85 [Disconnection in No. 5 fuel injector system]...................................................................................... 947 ENG-27 Error code E-86 [Disconnection in No. 6 fuel injector system]...................................................................................... 948 ENG-28 Error code E-8A [Short circuit in No. 1, No. 2, No. 3 fuel injector systems]....................................................................... 949 ENG-29 Error code E-8b [Short circuit in No. 4, No. 5, No. 6 fuel injector systems]....................................................................... 950 30 DISASSEMBLY AND ASSEMBLY........................................................................................................................................... 951 METHOD OF USING MANUAL............................................................................................................................................ 953 PRECAUTIONS WHEN CARRYING OUT OPERATION........................................................................................................................... 954 SPECIAL TOOL LIST................................................................................................................................................. 956 SKETCHES OF SPECIAL TOOLS......................................................................................................................................... 962 STARTING MOTOR.................................................................................................................................................... 965 Removal and Installation...................................................................................................................................... 965 ALTERNATOR........................................................................................................................................................ 966 Removal and Installation (Serial No.: 50001 β 52000).......................................................................................................... 966 Removal and Installation (Serial No.: 52001 and up)........................................................................................................... 967 ENGINE OIL COOLER................................................................................................................................................. 968 Removal....................................................................................................................................................... 968 Installation.................................................................................................................................................. 969 FUEL INJECTION PUMP............................................................................................................................................... 970 Removal and Installation...................................................................................................................................... 970 FUEL SUPPLY PUMP.................................................................................................................................................. 971 Removal....................................................................................................................................................... 971 Installation.................................................................................................................................................. 973 WATER PUMP........................................................................................................................................................ 974 Removal....................................................................................................................................................... 974 Installation.................................................................................................................................................. 975 NOZZLE HOLDER..................................................................................................................................................... 976 Removal and Installation...................................................................................................................................... 976 FUEL INJECTOR..................................................................................................................................................... 977 Removal....................................................................................................................................................... 977 Installation.................................................................................................................................................. 979 TURBOCHARGER...................................................................................................................................................... 981 Removal....................................................................................................................................................... 981 Installation.................................................................................................................................................. 982 ENGINE FRONT SEAL................................................................................................................................................. 984 Removal and Installation...................................................................................................................................... 984 ENGINE REAR SEAL.................................................................................................................................................. 985 Removal....................................................................................................................................................... 985 Installation.................................................................................................................................................. 986 CYLINDER HEAD..................................................................................................................................................... 988 Removal....................................................................................................................................................... 988 Installation.................................................................................................................................................. 996 RADIATOR..........................................................................................................................................................1001 Removal.......................................................................................................................................................1001 Installation..................................................................................................................................................1004 ENGINE............................................................................................................................................................1005 Removal.......................................................................................................................................................1005 Installation..................................................................................................................................................1013 DAMPER............................................................................................................................................................1014 Removal and Installation......................................................................................................................................1014 Disassembly...................................................................................................................................................1015 Assembly......................................................................................................................................................1018 TORQUE CONVERTER, TRANSMISSION....................................................................................................................................1023 Removal.......................................................................................................................................................1023 Installation..................................................................................................................................................1025 Disconnection.................................................................................................................................................1026 Connection....................................................................................................................................................1027 TORQUE CONVERTER..................................................................................................................................................1028 Disassembly...................................................................................................................................................1028 Assembly......................................................................................................................................................1032 TRANSMISSION......................................................................................................................................................1039 Disassembly...................................................................................................................................................1039 Assembly......................................................................................................................................................1056 TRANSFER..........................................................................................................................................................1073 Disassembly...................................................................................................................................................1073 Assembly......................................................................................................................................................1077 PARKING BRAKE.....................................................................................................................................................1082 Disassembly...................................................................................................................................................1082 Assembly......................................................................................................................................................1085 TRANSMISSION CONTROL VALVE........................................................................................................................................1090 Removal and Installation......................................................................................................................................1090 CENTER SUPPORT....................................................................................................................................................1091 Removal.......................................................................................................................................................1091 Installation..................................................................................................................................................1092 Disassembly...................................................................................................................................................1093 Assembly......................................................................................................................................................1095 DRIVE SHAFT.......................................................................................................................................................1098 Disassembly...................................................................................................................................................1098 Assembly......................................................................................................................................................1101 FRONT AXLE........................................................................................................................................................1104 Removal.......................................................................................................................................................1104 Installation..................................................................................................................................................1105 FRONT DIFFERENTIAL................................................................................................................................................1106 Removal.......................................................................................................................................................1106 Installation..................................................................................................................................................1108 REAR AXLE.........................................................................................................................................................1109 Removal.......................................................................................................................................................1109 Installation..................................................................................................................................................1114 REAR DIFFERENTIAL.................................................................................................................................................1115 Removal.......................................................................................................................................................1115 Installation..................................................................................................................................................1116 DIFFERENTIAL GEAR.................................................................................................................................................1117 Disassembly...................................................................................................................................................1117 Assembly......................................................................................................................................................1121 LIMITED SLIP DEFFERENTIAL.........................................................................................................................................1129 Disassembly...................................................................................................................................................1129 Assembly......................................................................................................................................................1133 FINAL DRIVE.......................................................................................................................................................1143 Disassembly...................................................................................................................................................1143 Assembly......................................................................................................................................................1146 ORBIT-ROLL........................................................................................................................................................1150 Removal and Installation......................................................................................................................................1150 Disassembly...................................................................................................................................................1151 Assembly......................................................................................................................................................1156 STEERING CYLINDER.................................................................................................................................................1163 Removal.......................................................................................................................................................1163 Installation..................................................................................................................................................1164 Disassembly...................................................................................................................................................1165 Assembly......................................................................................................................................................1167 STEERING VALVE....................................................................................................................................................1169 Removal.......................................................................................................................................................1169 Installation..................................................................................................................................................1171 BRAKE VALVE.......................................................................................................................................................1172 Removal.......................................................................................................................................................1172 Installation..................................................................................................................................................1173 SLACK ADJUSTER....................................................................................................................................................1174 Removal and Installation......................................................................................................................................1174 Disassembly...................................................................................................................................................1175 Assembly......................................................................................................................................................1176 BRAKE (Front, rear)...............................................................................................................................................1177 Removal and Installation......................................................................................................................................1177 Disassembly...................................................................................................................................................1178 Assembly......................................................................................................................................................1181 ACCUMULATOR CHARGE VALVE..........................................................................................................................................1185 Removal.......................................................................................................................................................1185 Installation..................................................................................................................................................1186 Disassembly...................................................................................................................................................1188 Assembly......................................................................................................................................................1190 HYDRAULIC PUMP....................................................................................................................................................1193 Removal.......................................................................................................................................................1193 Installation..................................................................................................................................................1194 HYDRAULIC TANK....................................................................................................................................................1195 Removal.......................................................................................................................................................1195 Installation..................................................................................................................................................1196 HYDRAULIC FILTER..................................................................................................................................................1197 Removal and Installation......................................................................................................................................1197 PPC VALVE.........................................................................................................................................................1198 Removal and Installation......................................................................................................................................1198 Disassembly and Assembly......................................................................................................................................1199 MAIN CONTROL VALVE................................................................................................................................................1200 Removal.......................................................................................................................................................1200 Installation..................................................................................................................................................1202 Disassembly...................................................................................................................................................1204 Assembly......................................................................................................................................................1208 BUCKET CYLINDER...................................................................................................................................................1211 Removal.......................................................................................................................................................1211 Installation..................................................................................................................................................1212 BOOM CYLINDER.....................................................................................................................................................1213 Removal.......................................................................................................................................................1213 Installation..................................................................................................................................................1214 BOOM AND BUCKET CYLINDERS.........................................................................................................................................1215 Disassembly...................................................................................................................................................1215 Assembly......................................................................................................................................................1217 CENTER HINGE PIN..................................................................................................................................................1220 Removal.......................................................................................................................................................1220 Installation..................................................................................................................................................1226 WORK EQUIPMENT....................................................................................................................................................1229 Removal.......................................................................................................................................................1229 Installation..................................................................................................................................................1233 BULKHEAD..........................................................................................................................................................1234 Removal.......................................................................................................................................................1234 Installation..................................................................................................................................................1238 ENGINE HOOD.......................................................................................................................................................1239 Removal.......................................................................................................................................................1239 Installation..................................................................................................................................................1240 FLOOR FRAME.......................................................................................................................................................1241 Removal.......................................................................................................................................................1241 Installation..................................................................................................................................................1246 COUNTERWEIGHT.....................................................................................................................................................1247 Removal and Installation......................................................................................................................................1247 FUEL TANK.........................................................................................................................................................1248 Removal.......................................................................................................................................................1248 Installation..................................................................................................................................................1251 CAB...............................................................................................................................................................1252 Removal.......................................................................................................................................................1252 Installation..................................................................................................................................................1254 AIR CONDITIONER UNIT..............................................................................................................................................1255 Removal.......................................................................................................................................................1255 Installation..................................................................................................................................................1256 AIR CONDITIONER CONDENSOR.........................................................................................................................................1257 Removal.......................................................................................................................................................1257 Installation..................................................................................................................................................1258 RECEIVER TANK.....................................................................................................................................................1259 Removal.......................................................................................................................................................1259 Installation..................................................................................................................................................1260 AIR CONDITIONER COMPRESSOR........................................................................................................................................1261 Removal.......................................................................................................................................................1261 Installation..................................................................................................................................................1262 40 MAINTENANCE STANDARD...............................................................................................................................................1263 ENGINE MOUNT......................................................................................................................................................1264 TRANSMISSION MOUNT................................................................................................................................................1265 DAMPER............................................................................................................................................................1266 TORQUE CONVERTER CHARGING PUMP....................................................................................................................................1267 TORQUE CONVERTER, PTO.............................................................................................................................................1268 TRANSMISSION......................................................................................................................................................1270 TRANSFER..........................................................................................................................................................1278 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE........................................................................................................................1280 LUBRICATION RELIEF VALVE..........................................................................................................................................1281 DRIVE SHAFT.......................................................................................................................................................1282 CENTER SUPPORT....................................................................................................................................................1283 DIFFERENTIAL......................................................................................................................................................1284 LIMITED SLIP DIFFERENTIAL.........................................................................................................................................1288 FINAL DRIVE.......................................................................................................................................................1290 AXLE MOUNT........................................................................................................................................................1292 CENTER HINGE PIN..................................................................................................................................................1294 STEERING COLUMN...................................................................................................................................................1296 STEERING PUMP.....................................................................................................................................................1297 STEERING VALVE....................................................................................................................................................1299 STEERING CYLINDER MOUNT...........................................................................................................................................1300 BRAKE VALVE.......................................................................................................................................................1302 SLACK ADJUSTER....................................................................................................................................................1305 BRAKE.............................................................................................................................................................1306 PARKING BRAKE.....................................................................................................................................................1308 HYDRAULIC PUMP....................................................................................................................................................1309 SWITCH, PPC PUMP..................................................................................................................................................1310 PPC VALVE.........................................................................................................................................................1311 CUT-OFF VALVE.....................................................................................................................................................1313 MAIN CONTROL VALVE................................................................................................................................................1314 HYDRAULIC CYLINDERS...............................................................................................................................................1318 BUCKET LINKAGE....................................................................................................................................................1320 BUCKET............................................................................................................................................................1322 BUCKET POSITIONER AND BOOM KICK-OUT...............................................................................................................................1323 ROPS CAB..........................................................................................................................................................1325 90 OTHERS.............................................................................................................................................................1327 TRANSMISSION......................................................................................................................................................1329 BRAKE PIPINGγSERIAL No.: 50001 β 52000............................................................................................................................1331 HYDRAULIC PIPINGγSERIAL No.: 50001 β 52000........................................................................................................................1333 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAMγSerial No.: 50001 β 52000................................................................................................1335 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH OPTIONAL SPECIFICATION)γSerial No.: 50001 β 52000..........................................................1337 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAMγSerial No.: 52001 and up.................................................................................................1339 ELECTRIC CIRCUIT DIAGRAM (1/4)γSerial No.: 50001 β 52000..........................................................................................................1341 ELECTRIC CIRCUIT DIAGRAM (2/4)γSerial No.: 50001 β 52000..........................................................................................................1343 ELECTRIC CIRCUIT DIAGRAM (3/4)γSerial No.: 50001 β 52000..........................................................................................................1345 ELECTRIC CIRCUIT DIAGRAM (4/4)γSerial No.: 50001 β 52000..........................................................................................................1347 ELECTRIC CIRCUIT DIAGRAM (1/5)γSerial No.: 52001 and up...........................................................................................................1349 ELECTRIC CIRCUIT DIAGRAM (2/5)γSerial No.: 52001 and up...........................................................................................................1351 ELECTRIC CIRCUIT DIAGRAM (3/5)γSerial No.: 52001 and up...........................................................................................................1353 ELECTRIC CIRCUIT DIAGRAM (4/5)γSerial No.: 52001 and up...........................................................................................................1355 ELECTRIC CIRCUIT DIAGRAM (5/5)γSerial No.: 52001 and up...........................................................................................................1357 ELECTRIC PARKING BRAKE CONTROL....................................................................................................................................1359 CONNECTOR ARRANGEMENT DIAGRAM (1/2)γSerial No.: 50001 β 52000.....................................................................................................1361 CONNECTOR ARRANGEMENT DIAGRAM (2/2)γSerial No.: 50001 β 52000.....................................................................................................1363 CONNECTOR ARRANGEMENT DIAGRAM (1/2)γSerial No.: 52001 and up......................................................................................................1366 CONNECTOR ARRANGEMENT DIAGRAM (2/2)γSerial No.: 52001 and up......................................................................................................1368
DESCRIPTION:
KOMATSU WA500-3 SHOP MANUAL SEBM009015 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
S.S 22/12/24
