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KOMATSU WA500-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A70001 and up) KOMATSU WA500-3 – PDF DOWNLOAD
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- KOMATSU WA500-3 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A70001 and up
- PUBLICATION NUMBER:CEBM001203
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KOMATSU WA500-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A70001 and up) KOMATSU WA500-3
KOMATSU WA500-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A70001 AND UP) KOMATSU WA500-3 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA500-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A70001 and up) KOMATSU WA500-3
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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. - 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” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU WA500-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A70001 and up) KOMATSU WA500-3
MAIN MENU.................................................................................................................................... 0 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 27 DIMENSIONS............................................................................................................................... 28 SPECIFICATIONS........................................................................................................................... 30 WEIGHT TABLE............................................................................................................................. 33 FUEL, COOLANT, AND LUBRICANTS............................................................................................................ 34 ENGINE OIL SPECIFICATIONS................................................................................................................ 35 TRANSMISSION, HYDRAULIC, AND BRAKE OIL................................................................................................... 36 AXLE OIL SPECIFICATIONS.................................................................................................................. 36 GREASE SPECIFICATIONS.................................................................................................................... 36 DIESEL FUEL SPECIFICATIONS............................................................................................................... 36 COOLANT SPECIFICATIONS................................................................................................................... 36 10 STRUCTURE AND FUNCTION.................................................................................................................... 43 GENERAL.................................................................................................................................. 44 RADIATOR AND OIL COOLER.................................................................................................................. 46 DAMPER................................................................................................................................... 47 TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................. 49 HYDRAULIC CIRCUIT FOR POWER TRAIN........................................................................................................ 50 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN................................................................................................ 51 TORQUE CONVERTER AND PTO................................................................................................................. 52 TRANSMISSION............................................................................................................................. 54 TRANSMISSION CONTROL VALVE............................................................................................................... 64 ECMV (ELECTRONIC CONTROL MODULATION VALVE)............................................................................................... 66 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE............................................................................................... 72 LUBRICATING RELIEF VALVE................................................................................................................. 74 TORQUE CONVERTER OIL FILTER.............................................................................................................. 75 PILOT FILTER............................................................................................................................. 76 TRANSFER................................................................................................................................. 77 DRIVE SHAFT.............................................................................................................................. 78 CENTER SUPPORT........................................................................................................................... 79 AXLE..................................................................................................................................... 80 DIFFERENTIAL............................................................................................................................. 82 FINAL DRIVE.............................................................................................................................. 86 AXLE MOUNT............................................................................................................................... 88 CENTER HINGE PIN......................................................................................................................... 90 TIRE AND WHEEL........................................................................................................................... 91 STEERING PIPING.......................................................................................................................... 92 ELECTRIC PARKING BRAKE CONTROL........................................................................................................... 283 STEERING COLUMN.......................................................................................................................... 93 STEERING VALVE........................................................................................................................... 94 ORBIT-ROLL VALVE......................................................................................................................... 108 STOP VALVE............................................................................................................................... 112 DIVERTER VALVE........................................................................................................................... 113 BRAKE CIRCUIT DIAGRAM.................................................................................................................... 117 BRAKE VALVE.............................................................................................................................. 118 CHARGE VALVE............................................................................................................................. 124 ACCUMULATOR (FOR BRAKE).................................................................................................................. 128 SLACK ADJUSTER........................................................................................................................... 129 BRAKE.................................................................................................................................... 132 PARKING BRAKE CONTROL.................................................................................................................... 134 PARKING BRAKE............................................................................................................................ 135 PARKING BRAKE SOLENOID VALVE............................................................................................................. 136 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE........................................................................................... 137 HYDRUALIC CIRCUIT SYSTEM................................................................................................................. 144 WORK EQUIPMENT LEVER LINKAGE............................................................................................................. 146 HYDRAULIC TANK........................................................................................................................... 147 ACCUMULATOR (FOR PPC VALVE).............................................................................................................. 150 PPC VALVE................................................................................................................................ 152 PPC RELIEF VALVE......................................................................................................................... 159 CUT-OFF VALVE............................................................................................................................ 160 MAIN CONTROL VALVE....................................................................................................................... 164 WORK EQUIPMENT LINKAGE................................................................................................................... 180 BUCKET................................................................................................................................... 182 BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................... 184 PROXIMITY SWITCH......................................................................................................................... 186 CAB...................................................................................................................................... 192 ROPS CANOPY.............................................................................................................................. 193 AIR CONDITIONER.......................................................................................................................... 194 AIR CONDITIONER PIPING............................................................................................................... 194 BASIC INFORMATION ON AIR CONDITIONERS................................................................................................ 195 UNITS RELATED TO REFRIGERATION....................................................................................................... 195 PRINCIPLE OF COOLING................................................................................................................. 199 REFRIGERANTS......................................................................................................................... 204 SAFETY PRECAUTIONS................................................................................................................... 204 REFRIGERATOR OIL (LUBE OIL).......................................................................................................... 205 AIR CONDITIONING CONDENSER............................................................................................................... 207 FUNCTION............................................................................................................................. 207 GENERAL DESCRIPTION.................................................................................................................. 207 AIR CONDITIONER COMPRESSOR............................................................................................................... 210 RECEIVER WITH SIGHT GLASS (LIQUID TANK).................................................................................................. 211 AIR CONDITIONER UNIT..................................................................................................................... 213 OUTLINE.............................................................................................................................. 213 ELECTRIC CIRCUIT DIAGRAM................................................................................................................. 214 MACHINE MONITOR SYSTEM................................................................................................................... 244 MAIN MONITOR............................................................................................................................. 245 MAINTENANCE MONITOR...................................................................................................................... 249 ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM............................................................................... 252 TRANSMISSION CONTROLLER.................................................................................................................. 264 SENSORS.................................................................................................................................. 266 ENGINE STARTING CIRCUIT.................................................................................................................. 272 ENGINE STOP CIRCUIT...................................................................................................................... 274 ETHER START CIRCUIT...................................................................................................................... 275 ELECTRIC TRANSMISSION CONTROL............................................................................................................ 276 COMBINATION SWITCH....................................................................................................................... 277 KICK-DOWN/HOLD SWITCH.................................................................................................................... 279 KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS.................................................................................................... 280 ELECTRIC PARKING BRAKE CONTROL........................................................................................................... 283 20 TESTING AND ADJUSTING..................................................................................................................... 295 STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS............................................................................................. 297 STANDARD VALUE TABLE FOR CHASSIS......................................................................................................... 298 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM............................................................................................... 303 SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING................................................................................... 316 SKETCHES FOR SPECIAL TOOLS............................................................................................................... 317 MEASURING ENGINE SPEED................................................................................................................... 318 MEASURING INTAKE MANIFOLD PRESSURE................................................................................................... 319 MEASURING INTAKE AIR RESTRICTION..................................................................................................... 320 MEASURING ENGINE LUBRICATING OIL PRESSURE............................................................................................ 321 MEASURING FUEL FILTER INLET RESTRICTION.............................................................................................. 322 MEASURING BLOW-BY PRESSURE........................................................................................................... 323 MEASURING EXHAUST BACK PRESSURE...................................................................................................... 324 MEASURING COOLANT TEMPERATURE........................................................................................................ 325 MEASURING AND ADJUSTING VALVE CLEARANCE.............................................................................................. 326 ALTERNATOR DRIVE BELT.................................................................................................................... 327 AIR CONDITIONER BELT..................................................................................................................... 328 MEASURING EXHAUST TEMPERATURE............................................................................................................ 329 EXHAUST GAS COLOR........................................................................................................................ 330 MEASURING ENGINE STALL SPEEDS............................................................................................................ 332 MEASURING TORQUE CONVERTER STALL......................................................................................................... 332 MEASURING HYDRAULIC STALL................................................................................................................ 333 MEASURING FULL STALL..................................................................................................................... 333 ADJUSTING ENGINE SPEED SENSOR............................................................................................................ 334 MEASURING SHIFT LEVERS................................................................................................................... 335 MEASURING ACCELERATOR PEDAL.............................................................................................................. 336 MEASURING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE................................................................................. 338 FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT............................................................................. 341 MOVING MACHINE WHEN TRANSMISSION VALVE FAILS............................................................................................. 342 TESTING AND ADJUSTING STEERING WHEEL..................................................................................................... 344 STEERING OIL PRESSURE.................................................................................................................... 346 STEERING STOP VALVE...................................................................................................................... 348 MEASURING BRAKE PEDAL.................................................................................................................... 349 MEASURING BRAKE PERFORMANCE.............................................................................................................. 350 TESTING BRAKE OIL PRESSURE............................................................................................................... 351 MEASURING BRAKE DISC WEAR................................................................................................................ 352 PARKING BRAKE PERFORMANCE................................................................................................................ 353 PARKING BRAKE OIL PRESSURE............................................................................................................... 354 PARKING BRAKE DISC WEAR.................................................................................................................. 356 MANUAL RELEASE METHOD FOR PARKING BRAKE.................................................................................................. 357 PPC OIL PRESSURE......................................................................................................................... 358 ADJUSTING PPC VALVE LINKAGE.............................................................................................................. 360 ACCUMULATOR CHARGE PRESSURE.............................................................................................................. 361 WORK EQUIPMENT HYDRAULIC PRESSURE........................................................................................................ 362 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................................................ 364 ADJUSTING WORK EQUIPMENT LEVER LINKAGE................................................................................................... 365 BLEEDING AIR ............................................................................................................................ 366 BUCKET POSITIONER........................................................................................................................ 367 BOOM POSITIONER.......................................................................................................................... 368 TRANSMISSION CONTROLLER.................................................................................................................. 370 ADJUSTING MAIN MONITOR (SPEED MODULE).................................................................................................... 372 TROUBLESHOOTING.......................................................................................................................... 375 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................................. 376 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................... 377 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................... 378 CHECKS BEFORE TROUBLESHOOTING............................................................................................................ 386 HANDLING CONNECTORS...................................................................................................................... 387 PRECAUTIONS WHEN TROUBLESHOOTING..................................................................................................... 388 METHOD OF READING ROUBLESHOOTING TABLES.............................................................................................. 390 PREVENTING RECURRENCE OF TROUBLE......................................................................................................... 392 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................... 395 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................... 404 EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANIS.................................................................................... 415 TRANSMISSION CONTROL SYSTEM.......................................................................................................... 415 MAIN MONITOR SYSTEM.................................................................................................................. 419 MAINTENANCE MONITOR SYSTEM........................................................................................................... 423 ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) CONTROL SYSTEM.................................................................... 427 JOYSTICK STEERING CONTROL SYSTEM..................................................................................................... 431 METHOD OF DISPLAYING ACTION AND FIALURE CODE......................................................................................... 433 CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION................................................................................ 435 TRANSMISSION CONTROLLER LED DISPLAY.................................................................................................. 439 METHOD OF USING JUDGEMENT TABLE ......................................................................................................... 441 METHOD OF USING JUDGEMENT CHARTS......................................................................................................... 443 METHOD OF USING MATRIX TROUBLESHOOTING TABLES............................................................................................ 445 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)............................................................................... 448 JUDGMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS...................................................................... 451 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEM ON MACHINE............................................................ 453 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM........................................................................ 461 T-1 FAILURE CODE [10](SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP LAMP RELAY) IS DISPLAYED.............. 463 T-2 FAILURE CODE [12](SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED...................... 464 T-3 FAILURE CODE [13](SHORT CIRCUIT, DISCONNECTIONS, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED..................... 465 T-4 FAILURE CODE [14] (SHORT CIRUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED.................... 466 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED................... 467 T-6 FAILURE CODE [16](SHORT CIRUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED..................... 468 T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOUCE IN 4TH SOLENOID) IS DISPLAYED.................... 469 T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.............................. 470 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED....................................... 471 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH................................................................. 475 T-11 FAILURE CODE [22](DISCONNECTIONS IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED.................................................... 478 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED..................................... 479 T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED ....................................................... 480 T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE SYSTEM) IS DISPLAYED........................................... 481 T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMC FILL SWITCH SYSTEM) IS DISPLAYED..................................................... 482 T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM) IS DISPLAYED..................................................... 482 T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM) IS DISPLAYED................................................... 483 T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM) IS DISPLAYED................................................... 483 T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM) IS DISPLAYED................................................... 484 T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED................................................... 484 T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM) IS DISPLAYED................................................ 485 T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD OR 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED.................................. 487 T-23 HOLD SWITCH SYSTEM.............................................................................................................. 489 T-24 KICK-DOWN SWITCH SYSTEM......................................................................................................... 489 T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM.............................................................................................. 491 T-26 NEUTRALIZER RELAY SIGNAL SYSTEM................................................................................................. 492 T-27 BUZZER SIGNAL SYSTEM............................................................................................................ 493 T-28 NETWORK SYSTEM.................................................................................................................. 494 T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM..................................................................................... 495 T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM..................................................................................... 496 T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM..................................................................... 497 T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM...................................................................................... 498 T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM...................................................................................... 498 T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM.................................................................................... 499 T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM.................................................................................... 499 T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM.................................................................................... 500 T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM.................................................................................... 500 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).......................................................................................... 502 TROUBLE DATA DISPLAY................................................................................................................. 504 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM................................................................................ 507 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM.................................................................................. 509 ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND HAZARD SYSTEM......................................................................... 510 M-1 MAIN MONITOR DOES NOT WORK....................................................................................................... 511 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP................................... 512 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY....................................................................................... 513 M-4 ABNORMALITY IN SHIFT INDICATOR................................................................................................... 514 A) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F................................................................................ 514 B) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R................................................................................ 514 C) DOES NOT DISPLAY N WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F............................. 514 D) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R......................... 515 E) DOES NOT DISPLAY 1ST-4TH...................................................................................................... 515 M-5 HIGH BEAM DOES NOT LIGHT UP...................................................................................................... 516 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................................................ 517 A) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP.................................................................................... 517 B) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP.................................................................................... 517 M-7 ABNORMALITY IN PARKING DISPLAY................................................................................................... 518 A) PARKING LAMP DISPLAY DOES NOT LIGHT UP........................................................................................ 518 B) PARKING LAMP DISPLAY STAYS LIGHTED UP......................................................................................... 518 M-9 NIGHT LIGHTING DOES NOT LIGHT UP................................................................................................. 520 M-10 ABNORMALITY IN FRONT WORKING LAMP............................................................................................... 521 A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP....................................................................... 521 B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.................................................................. 521 C) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP.................................................................. 521 M-11 ABNORMALITY IN REAR WORKING LAMP................................................................................................ 523 A) NEIGHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP........................................................................ 523 B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.................................................................. 523 C) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP.................................................................. 523 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF............................................................................................. 525 A) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE..... 525 B) WHEN MONITOR SWITCH IS OFF MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED.................. 525 C) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED.............. 525 D) CUT-OFF FUNCTION IS ALWAYS ACTUATE REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)...................... 525 E) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED....................... 526 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING................................................................................... 527 A) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N.... 527 B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP....................................... 527 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED....... 529 A) ACTUATED CONTINUOUSLY......................................................................................................... 529 B) NOT ACTUATED.................................................................................................................. 529 M-15 ABNORMALITY IN BUZZER........................................................................................................... 530 A) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS)(DURING SELF-CHECK)........................................ 530 B) BUZZER ALWAYS SOUNDS.......................................................................................................... 530 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY........................................................................... 531 M-17 ABNORMALITY IN FAILURE DISPLAY MODE............................................................................................. 532 A) DOES NOT ENTER FAILURE DISPLAY MODE........................................................................................... 532 B) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE................................................. 532 M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER.......................................................................... 533 M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY................................................................................ 534 A) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP........................................................................... 534 B) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP............................................................................ 534 M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY............................................................................. 535 M-21 ABNORMALITY IN AUTO-GREASING SYSTEM............................................................................................. 537 A) FORCED GREASING CANNOT BE CARRIED OUT......................................................................................... 537 B) MONITOR DISPLAY FLASHES RAPIDLY (2 TIME/SEC).................................................................................. 537 C) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)................................................... 537 D) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY.................................................. 538 E) MONITOR DISPLAY GOES OUT...................................................................................................... 538 M-22 ABNORMALITY IN ECSS SYSTEM...................................................................................................... 539 A) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED................................................................................ 539 B) MONITOR DISPLAY LIGHT UP BUT ECSS FUNCIOTN DOES NOT WORK...................................................................... 539 M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR ( ABNORMALITY IN NETWORK............................................................... 540 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)................................................................................... 542 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM................................................................................ 545 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC, MAINTENANCE MONITOR DOES NOT ..... 547 A) NO LAMPS ON MAINTENANCE MONITOR DOES NOT WORK................................................................................. 547 B) SOME LAMPS DO NOT LIGHT UP.................................................................................................... 547 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)............ 548 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNE ON (WITHIN 3 SECS), NO LAMPS ON MAINTENANCE MONITOR GO OUT..... 549 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH............................................................ 550 A) ENGINE OIL LEVEL DISPLAY FLASHES.............................................................................................. 550 B) ENGINE WATER LEVEL DISPLAY FLASHES............................................................................................ 552 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH.......................................................... 553 A) ENGINE OIL PRESSURE DISPLAY FLASHES........................................................................................... 553 B) BATTERY CHARGE LEVEL DISPLAY FLASHES.......................................................................................... 554 C) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE OIL PRESSURE IS CORRECT)................................................... 555 D) AIR CLEANER DISPLAY FLASHES .................................................................................................. 556 K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND..................................................................... 557 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS............................................................. 558 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH............................................ 559 A) CHECK LAMP.................................................................................................................... 559 B) CAUTION LAMP.................................................................................................................. 559 K-9 THERE IS NO ABNORMALITY IN MAINTENANCEMONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHT UP....................... 560 A) CHECK LAMP.................................................................................................................... 560 B) CAUTION LAMP.................................................................................................................. 560 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)......... 561 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF NIGHT LIGHTING STAYS LIGHTED UP........................................... 562 K-12 SERVICE METER DOES NOT WORK..................................................................................................... 563 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED............................................................................ 563 K-14 ABNORMALITY IN GAUGE ITEMS...................................................................................................... 564 A) ABNORMALITY IN FUEL GAUGE..................................................................................................... 564 B) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE................................................................................. 565 C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE......................................................................... 566 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................................................ 567 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING/STOP SYSTEM............................................................. 568 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM.................................................................................. 570 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM.................................................................................. 571 ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER SYSTEM............................................................ 572 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM........................................................................ 573 E-1 ENGINE DOES NOT START............................................................................................................ 575 A) ENGINE DOES NOT START......................................................................................................... 575 B) STARTING MOTOR TURNS.......................................................................................................... 579 E-2 ENGINE DOES NOT STOP............................................................................................................. 581 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING........................................................................................... 581 E-4 NOT USED......................................................................................................................... 584 E-5 PARKING BRAKE DOES NOT HAVE EFFECT............................................................................................... 584 A) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (ACTUATED)................................................. 584 B) PARKING BRAKE HAS NOT EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKES).................................... 584 E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING............................................................................... 585 E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...................................................................... 587 E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)......................... 587 E-9 KICK-DOWN SWITCH DOES NOT WORK................................................................................................... 589 A) KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS).................................... 589 B) KICK-DOWN IS NOT CANCELED..................................................................................................... 590 E-10 BOOM KICK-OUT CANNOT BE USED.................................................................................................... 591 E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION....................................................................................... 595 E-12 ABNORALITY IN LIGHTING UP OF FRONT WORKING LAMP................................................................................. 598 E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP................................................................................. 598 E-14 ABNORMALITY IN TRANSMISSION CUT-OFF............................................................................................. 598 E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING .................................................................................. 598 E-16 ABNORMALITY IN BUZZER........................................................................................................... 598 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).............................................................................. 600 POWER TRAIN.......................................................................................................................... 601 H-1 MACHINE DOES NOT START....................................................................................................... 601 H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES, DOES NOT SHIFT GEAR.................................... 604 H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE ARE SHIFTING GEAR...................................................................... 608 H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OF SHIFTING GEAR.................................................................... 610 H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..................................................................................... 612 STEERING SYSTEM...................................................................................................................... 613 H-6 STEERING WHEEL DOES NOT TURN................................................................................................. 613 H-7 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]............................................................................... 614 H-8 TURNING, RESPONSE OF STEERING IS POOR........................................................................................ 616 H-9 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]................................................................ 618 H-10 STEERING IS HEAVY........................................................................................................... 621 H-11 JOYSTICK STEERING IS HEAVY ................................................................................................. 621 H-12 STEERING WHEEL SHAKES OR JERKS.............................................................................................. 622 H-13 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK)......................................................... 623 H-14 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING ..................................................... 624 BRAKE SYSTEM......................................................................................................................... 625 H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.......................................................................... 625 H-16 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG................................................................................ 627 H-17 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR....................................................................... 628 H-18 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)........................................... 629 WORK EQUIPMENT....................................................................................................................... 630 H-19 NEITHER BOOM NOR BUCKET MOVE................................................................................................ 630 H-20 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER................................................................................. 631 H-21 BOOM DOES NOT MOVE.......................................................................................................... 632 H-22 NOT USED.................................................................................................................... 634 H-23 BOOM IS SLOW OR BOOM LACKS POWER............................................................................................ 634 H-24 NOT USED.................................................................................................................... 634 H-25 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT................................................................ 636 H-27 NOT USED.................................................................................................................... 638 H-28 EXCESSIVE HYDRAULIC DRIFT OF BOOM........................................................................................... 638 H-29 BUCKET DOES NOT MOVE........................................................................................................ 639 H-30 BUCKET IS SLOW OR LACKS POWER............................................................................................... 640 H-31 EXCESSIVE HYDRUALIC DRIFT OF BUCKET......................................................................................... 641 H-32 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]................................................. 642 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE)............................................................ 644 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM..................................................................................... 645 ELECTRICAL CIRCUIT DIAGRAM FOR ECSS.................................................................................................. 647 D-1 ECSS DOES NOT WORK............................................................................................................... 648 A) ERROR CODE [D0] IS DISPLAYED.................................................................................................. 649 B) ERROR CODE [D1] IS DISPLAYED.................................................................................................. 649 C) ERROR CODE [D2] IS DISPLAYED.................................................................................................. 650 D) ERROR CODE [D3] IS DISPLAYED.................................................................................................. 650 E) NO ABNORMALITY DISPLAY IS GIVEN............................................................................................... 652 D-2 ECSS CANNOT BE CANCELED.......................................................................................................... 655 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE).......................................................................... 656 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS......................................................................... 657 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR.................................................................................... 659 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM....................................................................................... 663 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION DISPLAY OUTPUT) IS DISPLAYED.......................................... 664 J-2 FAILURE CODE [57](SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED.................................. 665 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED.................................. 666 J-4 FAILURE CODE [59](SHORT CIRUIT IN STEERING RIGHT SOLENOID (HOT END) IS DISPLAYED................................................. 667 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED............................................... 668 J-6 FAILURE CODE [61](SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED............................... 669 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IS JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED................................ 670 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMTER SYSTEM) IS DISPLAYED (NOT USED).......... 672 J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE............................................................................................. 672 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM........................................................................... 673 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID........................................................................................ 674 J-12 DISCONNECTION IN STEERING LEFT SOLENOID......................................................................................... 675 TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM (C MODE).......................................................... 676 ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM................................................... 679 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM................................................................................ 681 C-1 WHEN ENGINE IS RUNNING, ENGINE OIL LEVEL DISPLAY SHOWS 'ABNORMAL"................................................................ 683 C-2 WHEN ENGINE IS RUNNING, BATTERY ELECTROLYTE LEVEL DISPLAY SHOWS " ABNORMAL"...................................................... 684 C-3 ABNORMALITY IN ENGINE COOLANT LEVEL DISPLAY...................................................................................... 685 A) DISPLAY SHOWS "ABNORMAL"...................................................................................................... 685 B) DISPLAY SHOWS "DISCONNECTION"................................................................................................. 685 C) DISPLAY SHOWS "SHORT CIRCUIT"................................................................................................. 685 C-4 ABNORMALITY IN BRAKE OIL PRESSURE DISPLAY ....................................................................................... 687 A) WHEN ENGINE IS RUNNING, DISPLAY SHOWS "ABNORMAL".............................................................................. 687 B) DISPLAY SHOWS "DISCONNECTION"................................................................................................. 688 C) DISPLAY SHOWS "SHORT CIRCUIT"................................................................................................. 688 C-5 ABNORMALITY IN ENGINE OIL PRESSURE DISPLAY....................................................................................... 689 A) WHEN ENGINE IS RUNNING, DISPLAY SHOWS "ABNORMAL".............................................................................. 689 B) WHEN ENGINE IS STOPPED OR RUNNING, DISPLAY SHOWS "DISCONNECTION".............................................................. 689 C) ONLY WHEN ENGINE IS STOPPED, DISPLAY SHOWS "DISCONNECTION".................................................................... 689 D) DISPLAY SHOWS "SHORT CIRCUIT"................................................................................................. 690 C-6 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), BATTERY CHARGE DISPLAY SHOWS "ABNORMAL".......................................... 691 C-7 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), AIR CLEANER DISPLAY SHOWS "ABNORMAL"............................................. 692 C-8 CAUTION ITEM DISPLAY SHOWS "ABNORMAL", BUT ALARM BUZZER DOES NOT SOUND........................................................... 693 C-9 MONITOR DISPLAY DOES NOT SHOW "ABNORMAL", BUT ALARM BUZZER SOUNDS................................................................ 694 C-10 CAUTION ITEM DISPLAY SHOWS "ABNORMAL," BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH............................... 695 A) CHECK LAMP.................................................................................................................... 695 B) CAUTION LAMP.................................................................................................................. 695 C-11 MONITOR DISPLAY DOES NOT SHOW ANY ABNORMALITY, BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHT UP............................. 696 A) CHECK LAMP.................................................................................................................... 696 B) CAUTION LAMP.................................................................................................................. 696 C-12 SERVICE METER DOES NOT WORK..................................................................................................... 697 C-13 SERVICE METER IS RUNNING WHEN ENGINE IS STOPPED................................................................................. 697 C-14 ABNORMALITY IN FUEL GAUGE....................................................................................................... 698 A) DISPLAY SHOWS "DISCONNECTION" OF LOW FUEL LEVEL............................................................................... 698 B) DISPLAY ALWAYS SHOWS FULL AND DOES NOT GO DOWN................................................................................ 698 C-15 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE................................................................................... 699 A) DISPLAY SHOWS "SHORT CIRCUIT"................................................................................................. 699 B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE.................................................................................. 699 C-16 ABNORMILITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE........................................................................... 700 A) DISPLAY SHOWS "SHORT CIRCUIT"................................................................................................. 700 B) DISPLAY ALWAYS SHOWS LOWEST LEVEL AND DOES NOT GO UP.......................................................................... 700 C-17 WHEN STARTING SWITCH IS TURNED TO ON, MONITOR IS NOT ACTUATED (KOMATSU IS NOT DISPLAYED)........................................ 701 A) MAIN MONITOR CHECK LAMPS DO NOT LIGHT UP...................................................................................... 701 B) MAIN MONITOR CHECK LAMPS LIGHT UP............................................................................................. 702 C-18 DOES NOT SWITCH TO WORKING MEMORY (ENGINE RUNNING) MODE, OR SWITCHES TO CHECK BEFORE STARTING MODE WHEN ENGINE IS RUNNING ...... 703 C-19 ABNORMALITY IN MDC MONITOR DISPLAY ............................................................................................. 704 A) DISPLAY COLOR IS NORMAL....................................................................................................... 704 B) DISPLAY FLICKERS.............................................................................................................. 704 C-20 EVEN WHEN SWITCH IS OPERATED, NOTHING FUNCTIONS................................................................................. 705 C-21 DOES NOT SWITCH TO TV/VIDEO MODE................................................................................................ 707 A) STAYS AT PARKING BRAKE APPLIED DISPLAY........................................................................................ 707 B) DISPLAY DOES NOT LIGHT UP..................................................................................................... 709 C-22 ABNORMALITY IN MEMORY DATA...................................................................................................... 711 A) LOAD METER DATA IS NOT SAVED TO MEMORY........................................................................................ 711 B) MAINTENANCE TIME IS NOT SAVED TO MEMORY....................................................................................... 711 C-23 ENGINE SPEED STAY AT 0 RPM...................................................................................................... 712 C-24 PRESSURE SENSOR DISPLAY SHOWS "DISCONNECTION"................................................................................... 713 A) SENSOR POWER SOURCE DISPLAY SHOWS "ABNORMAL".................................................................................. 713 B) ONLY PRESSURE SENSOR DISPLAY SHOWS "DISCONNECTION"............................................................................ 713 C-25 LOAD METER CANNOT WEIGH LOAD.................................................................................................... 714 A) CANNOT CARRY OUT CALIBRATION.................................................................................................. 714 B) CAN CARRY OUT CALIBRATION.................................................................................................... 715 C-26 ABNORMALITY IS LEVER SWITCH..................................................................................................... 716 A) SUB-TOTAL SWITCH DOES NOT WORK................................................................................................ 716 B) CANCEL SWITCH DOES NOT WORK................................................................................................... 716 C-27 PRINTER DOES NOT PRINT OUT...................................................................................................... 717 C-28 ABNORMALITY IN ANTENNA SYSTEM................................................................................................... 718 C-29 ABNORMALITY IN SPEAKER SYSTEM................................................................................................... 719 A) ABNORMALITY IN RIGHT SPEAKER.................................................................................................. 719 B) ABNORMALITY IN LEFT SPEAKER................................................................................................... 719 TROUBLESHOOTING AIR CONDITIONING......................................................................................................... 720 AIR CONDITIONER/HEATER (DENSO)....................................................................................................... 721 VISUAL AND AUDIBLE INSPECTION.................................................................................................... 721 TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)........................................................................ 722 TROUBLESHOOTING THE ELECTRICAL CIRCUIT........................................................................................... 726 COOLER CIRCUIT TROUBLESHOOTING................................................................................................... 730 WIRING DIAGRAM....................................................................................................................... 738 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................. 740 PRECAUTIONS WHEN CARRYING OUT OPERATIONS................................................................................................. 742 SPECIAL TOOL LIST........................................................................................................................ 745 SKETCHES OF SPECIAL TOOLS................................................................................................................ 750 STARTING MOTOR ASSEMBLY.................................................................................................................. 753 REMOVAL.............................................................................................................................. 753 INSTALLATION......................................................................................................................... 753 ALTERNATOR ASSEMBLY...................................................................................................................... 754 REMOVAL.............................................................................................................................. 754 INSTALLATION ........................................................................................................................ 754 ENGINE OIL COOLER ....................................................................................................................... 755 REMOVAL.............................................................................................................................. 755 INSTALLATION......................................................................................................................... 755 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 756 REMOVAL.............................................................................................................................. 756 INSTALLATION......................................................................................................................... 756 WATER PUMP ASSEMBLY...................................................................................................................... 757 REMOVAL.............................................................................................................................. 757 INSTALLATION......................................................................................................................... 757 INJECTOR ASSEMBLY........................................................................................................................ 758 REMOVAL.............................................................................................................................. 758 INSTALLATION......................................................................................................................... 758 TURBOCHARGER ASSEMBLY.................................................................................................................... 759 REMOVAL.............................................................................................................................. 759 INSTALLATION......................................................................................................................... 759 AFTER COOLER ASSEMBLY.................................................................................................................... 761 REMOVAL.............................................................................................................................. 761 INSTALLATION......................................................................................................................... 762 CYLINDER HEAD ASSEMBLY................................................................................................................... 763 REMOVAL.............................................................................................................................. 763 INSTALLATION ........................................................................................................................ 765 RADIATOR ASSEMBLY........................................................................................................................ 769 REMOVAL ............................................................................................................................. 769 INSTALLATION......................................................................................................................... 770 DAMPER ASSEMBLY.......................................................................................................................... 771 REMOVAL ............................................................................................................................. 771 INSTALLATION......................................................................................................................... 771 DISASSEMBLY.......................................................................................................................... 771 ASSEMBLY............................................................................................................................. 775 TORQUE CONVERTER AND TRANSMISSION........................................................................................................ 780 REMOVAL.............................................................................................................................. 780 INSTALLATION ........................................................................................................................ 783 DISCONNECTION........................................................................................................................ 784 CONNECTION........................................................................................................................... 784 TORQUE CONVERTER ASSEMBLY................................................................................................................ 785 DISASSEMBLY.......................................................................................................................... 785 ASSEMBLY............................................................................................................................. 789 TRANSMISSION ASSEMBLY.................................................................................................................... 797 DISASSEMBLY ......................................................................................................................... 797 ASSEMBLY............................................................................................................................. 814 TRANSFER ASSEMBLY........................................................................................................................ 831 DISASSEMBLY.......................................................................................................................... 831 ASSEMBLY............................................................................................................................. 835 PARKING BRAKE ASSEMBLY................................................................................................................... 840 DISASSEMBLY.......................................................................................................................... 840 ASSEMBLY............................................................................................................................. 843 TRANSMISSION CONTROL VALVE ASSEMBLY (ECMV ASSEMBLY)...................................................................................... 847 REMOVAL.............................................................................................................................. 847 INSTALLATION......................................................................................................................... 847 CENTER SUPPORT ASSEMBLY.................................................................................................................. 848 REMOVAL.............................................................................................................................. 848 DISASSEMBLY.......................................................................................................................... 850 ASSEMBLY............................................................................................................................. 852 DISASSEMBLY OF DRIVE SHAFT............................................................................................................... 855 ASSEMBLY OF DRIVE SHAFT.................................................................................................................. 858 REMOVAL OF FRONT AXLE ASSEMBLY........................................................................................................... 861 INSTALLATION OF FRONT AXLE ASSEMBLY...................................................................................................... 862 REMOVAL OF FRONT DIFFERENTIAL ASSEMBLY................................................................................................... 863 INSTALLATION OF FRONT DIFFERENTIAL ASSEMBLY.............................................................................................. 865 REMOVAL OF REAR AXLE ASSEMBLY............................................................................................................ 866 INSTALLATION OF REAR AXLE ASSEMBLY....................................................................................................... 871 REMOVAL OF REAR DIFFERENTIAL ASSEMBLY.................................................................................................... 872 INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY............................................................................................... 873 DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY................................................................................................ 874 FINE DISASSEMBLY OF PINION ASSEMBLY...................................................................................................... 876 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY...................................................................................... 877 FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY......................................................................................... 878 FINE ASSEMBLY OF PINION ASSEMBLY......................................................................................................... 879 ASSEMBLY OF DIFFERENTIAL ASSEMBLY........................................................................................................ 880 DISASSEMBLY OF FINAL DRIVE ASSEMBLY...................................................................................................... 886 ASSEMBLY OF FINAL DRIVE ASSEMBLY......................................................................................................... 889 REMOVAL OF ORBIT ROLL ASSEMBLY........................................................................................................... 893 INSTALLATION OF ORBIT-ROLL ASSEMBLY...................................................................................................... 893 DISASSEMBLY OF ORBIT-ROLL ASSEMBLY....................................................................................................... 894 ASSEMBLY OF ORBIT-ROLL ASSEMBLY.......................................................................................................... 899 REMOVAL OF STEERING CYLINDER ASSEMBLY.................................................................................................... 906 INSTALLATION OF STEERING CYLINDER ASSEMBLY............................................................................................... 907 DISASSEMBLY OF STEERING CYLINDER ASSEMBLY................................................................................................ 908 ASSEMBLY OF STEERING CYLINDER ASSEMBLY................................................................................................... 910 REMOVAL OF STEERING VALVE ASSEMBLY....................................................................................................... 912 INSTALLATION OF STEERING VALVE ASSEMBLY.................................................................................................. 914 REMOVAL OF BRAKE VALVE ASSEMBLY.......................................................................................................... 915 INSTALLATION OF BRAKE VALVE ASSEMBLY..................................................................................................... 916 REMOVAL OF SLACK ADJUSTER ASSEMBLY....................................................................................................... 917 INSTALLATION OF SLACK ADJUSTER ASSEMBLY.................................................................................................. 917 DISASSEMBLY OF SLACK ADJUSTER............................................................................................................ 918 ASSEMBLY OF SLACK ADJUSTER............................................................................................................... 919 REMOVAL OF BRAKE ASSEMBLY (FRONT, REAR).................................................................................................. 920 INSTALLATION OF BRAKE ASSEMBLY (FRONT, REAR)............................................................................................. 920 DISASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR).............................................................................................. 921 ASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR)................................................................................................. 924 REMOVAL OF HYDRAULIC PUMP (SWITCH & PPC, LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY....................................... 928 INSTALLATION OF HYDRAULIC PUMP (SWITCH & PPC LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY................................... 929 REMOVAL OF HYDRAULIC TANK ASSEMBLY....................................................................................................... 930 INSTALLATION OF HYDRAULIC TANK ASSEMBLY.................................................................................................. 931 REMOVAL OF HYDRAULIC FILTER ASSEMBLY..................................................................................................... 932 INSTALLATION OF HYDRAULIC FILTER ASSEMBLY................................................................................................ 932 REMOVAL OF PPC VALVE ASSEMBLY............................................................................................................ 933 INSTALLATION OF PPC VALVE ASSEMBLY....................................................................................................... 933 DISASSEMBLY OF PPC VALVE ASSEMBLY........................................................................................................ 934 ASSEMBLY OF PPC VALVE ASSEMBLY........................................................................................................... 934 REMOVAL OF MAIN CONTROL VALVE ASSEMBLY................................................................................................... 935 INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY.............................................................................................. 937 ASSEMBLY OF MAIN CONTROL VALVE........................................................................................................... 942 REMOVAL OF BUCKET CYLINDER ASSEMBLY...................................................................................................... 945 INSTALLATION OF BUCKET CYLINDER ASSEMBLY................................................................................................. 946 REMOVAL OF BOOM CYLINDER ASSEMBLY........................................................................................................ 947 INSTALLATION OF BOOM CYLINDER ASSEMBLY................................................................................................... 948 DISASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY........................................................................................ 949 ASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY........................................................................................... 951 REMOVAL OF CENTER HINGE PIN.............................................................................................................. 954 INSTALLATION OF CENTER HINGE PIN......................................................................................................... 960 REMOVAL OF WORK EQUIPMENT................................................................................................................ 963 INSTALLATION OF WORK EQUIPMENT ASSEMBLY.................................................................................................. 967 REMOVAL OF BULKHEAD ASSEMBLY............................................................................................................. 968 INSTALLATION OF BULKHEAD ASSEMBLY........................................................................................................ 969 REMOVAL OF ENGINE HOOD ASSEMBLY.......................................................................................................... 970 INSTALLATION OF ENGINE HOOD ASSEMBLY..................................................................................................... 970 REMOVAL OF FLOOR FRAME ASSEMBLY.......................................................................................................... 971 INSTALLATION OF FLOOR FRAME ASSEMBLY..................................................................................................... 973 REMOVAL OF COUNTERWEIGHT................................................................................................................. 974 INSTALLATION OF COUNTERWEIGHT............................................................................................................ 974 REMOVAL OF FUEL TANK ASSEMBLY............................................................................................................ 975 INSTALLATION OF FUEL TANK ASSEMBLY....................................................................................................... 976 REMOVAL OF CAB ASSEMBLY.................................................................................................................. 977 INSTALLATION OF CAB ASSEMBLY............................................................................................................. 979 REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY................................................................................................. 980 INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY............................................................................................ 981 REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY............................................................................................ 982 INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY....................................................................................... 982 REMOVAL OF RECEIVER TANK................................................................................................................. 983 INSTALLATION OF RECEIVER TANK............................................................................................................ 983 REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY........................................................................................... 984 INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................................... 984 40 MAINTENANCE STANDARD...................................................................................................................... 986 ENGINE MOUNT............................................................................................................................. 987 TRANSMISSION MOUNT....................................................................................................................... 988 TORQUE CONVERTER CHARGING PUMP........................................................................................................... 989 DAMPER................................................................................................................................... 991 TORQUE CONVERTER AND PTO................................................................................................................. 993 TRANSMISSION............................................................................................................................. 995 TRANSFER................................................................................................................................. 999 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE...............................................................................................1001 LUBRICATION RELIEF VALVE.................................................................................................................1002 DRIVE SHAFT..............................................................................................................................1003 CENTER SUPPORT...........................................................................................................................1004 DIFFERENTIAL.............................................................................................................................1005 FINAL DRIVE..............................................................................................................................1009 AXLE MOUNT...............................................................................................................................1011 CENTER HINGE PIN.........................................................................................................................1013 STEERING COLUMN..........................................................................................................................1015 STEERING PUMP............................................................................................................................1016 STEERING VALVE...........................................................................................................................1017 STEERING CYLINDER MOUNT..................................................................................................................1018 BRAKE VALVE..............................................................................................................................1019 SLACK ADJUSTER...........................................................................................................................1023 BRAKE....................................................................................................................................1025 PARKING BRAKE............................................................................................................................1027 HYDRAULIC PUMP...........................................................................................................................1029 SWITCH AND PPC PUMP......................................................................................................................1030 PPC VALVE................................................................................................................................1031 CUT-OFF VALVE............................................................................................................................1033 MAIN CONTROL VALVE.......................................................................................................................1035 HYDRAULIC CYLINDERS......................................................................................................................1039 BUCKET LINKAGE...........................................................................................................................1041 BUCKET...................................................................................................................................1043 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................1044 ROPS CAB.................................................................................................................................1045
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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2 reviews for KOMATSU WA500-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A70001 and up) KOMATSU WA500-3 – PDF DOWNLOAD
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Kingston Solomon –
Krew –
had a good experience