Komatsu WA500-3 WHEEL LOADER Shop Manual CEBM001203 PDF

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Komatsu WA500-3 WHEEL LOADER Shop Manual CEBM001203  – PDF DOWNLOAD

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Komatsu WA500-3 WHEEL LOADER Shop Manual CEBM001203  – PDF DOWNLOAD

Language : English
Pages : 1046
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA500-3 WHEEL LOADER Shop Manual CEBM001203  – PDF DOWNLOAD

• SERIAL NUMBERS WA500-3LE A70001 and up
• ENGINE NTA14C

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

DESCRIPTION:

Komatsu WA500-3 WHEEL LOADER Shop Manual CEBM001203  – PDF DOWNLOAD

• SERIAL NUMBERS WA500-3LE A70001 and up
• ENGINE NTA14C

G.B  21/12/24