Komatsu WA500-3H Wheel Loader Repair Manual VEBM500100 PDF

Description

Komatsu WA500-3H Wheel Loader Shop Manual VEBM500100 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-3H Wheel Loader Shop Manual VEBM500100 – PDF DOWNLOAD 

Language : English
Pages : 986
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu WA500-3H Wheel Loader Shop Manual VEBM500100 – PDF DOWNLOAD 

SERIAL NUMBER WA500H20051 and up

WA500-3H 1
CONTENTS 3
00 SAFETY 4
SAFETY 4
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 10
COATING MATERIALS 12
STANDARD TIGHTENING TORQUE 14
ELECTRIC WIRE CODE 16
CONVERSION TABLES 17
01 GENERAL 23
SPECIFICATIONS 25
WEIGHT TABLE 28
FUEL, COOLANT AND LUBRICATNTS 29
10 STRUCTURE AND FUNCTION 39
GENERAL 43
RADIATOR AND OIL COOLER 45
DAMPER 46
TORQUE CONVERTER AND TRANSMISSION PIPING 48
HYDRAULIC CIRCUIT FOR POWER TRAIN 50
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 51
TORQUE CONVERTER AND PTO 52
TRANSMISSION 54
TRANMISSION 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 88
FINAL DRIVE 88
AXLE MOUNT 90
CENTER HINGE PIN 92
TIRE AND WHEEL 93
STEERING PIPING 94
STEERING VALVE 96
STOP VALVE 114
DIVERTER VALVE 115
BRAKE 119
PARKING BRAKE 136
HYDRAULIC 140
WORK EQUIPMENT 178
CAB 187
ROPS CANOPY 188
AIR CONDITIONER 189
MONITOR SYSTEMS 207
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM 215
ECSS SYSTEM 227
TRANSMISSION CONTROLLER 232
SENSORS 234
ELECTRICAL 240
20 TESTING, ADJUSTING AND TROUBLESHOOTING 267
STANDARD VALUE TABLE FOR ENGINE – IN CHASSIS 271
STANDARD VALUE TABLE FOR CHASSIS 272
SKETCHES OF SPECIAL TOOLS 290
ENGINE 291
TORQUE CONVERTER STALL SPEEDS 292
AIR CONDITIONER BELT 292
SHIFT LEVERS 293
ACCELERATOR PEDAL 294
TORQUE CONVERTER AND TRANSMISSION 296
STEERING WHEEL 304
STEERING OIL PRESSURE 306
STEERING STOP VALVE 308
BRAKE PEDAL 309
BRAKE PERFORMANCE 310
TESTING BRAKE OIL PRESSURE 311
BRAKE DISC WEAR 312
PARKING BRAKE 313
PPC VALVE 318
ACCUMULATOR 321
WORK EQUIPMENT 322
BLEEDING AIR 326
BUCKET POSITIONER 327
BOOM POSITIONER 328
TRANSMISSION CONTROLLER 330
MAIN MONITOR 332
TROUBLESHOOTING GENERAL 335
POINTS TO REMEMBER WHEN TROUBLESHOOTING 337
SEQUENCE OF EVENTS IN TROUBLESHOOTING 339
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 340
CHECKS BEFORE TROUBLESHOOTING 348
JUDGEMENT OF POWER TRAIN 349
PRECAUTIONS WHEN TROUBLESHOOTING 350
PREVENTING RECURRENCE OF TROUBLE 353
METHOD OF USING TROUBLESHOOTING CHARTS 354
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 356
METHOD OF USING ENGINE RELATED CHARTS 358
TROUBLESHOOTING CONNECTORS 363
CONNECTOR ARRANGEMENT DIAGRAM 365
CONNECTOR NUMBERS, TYPES AND PINS 366
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 375
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM 387
EXPLANATION OF FUNCTIONS OF ECM 388
METHOD OF DISPLAYING ACTION AND FAILURE CODE 407
CHART OF ACTION CODES, FAILURE CODES AND RE-ENACTION 409
TRANSMISSION CONTROLLER LED DISPLAY 412
TROUBLESHOOTING OF ECSS (D MODE) 415
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM 416
D-1 ECSS DOES NOT WORK 418
D-2 ECSS CANNOT BE CANCELED 421
TROUBLESHOOTING OF CHASSIS ELECTRICAL SYSTEM (E MODE) 423
E-1 ENGINE DOES NOT START 424
E-2 ENGINE DOES NOT STOP 432
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 434
E-5 PARKING BRAKE DOES NOT HAVE EFFECT 436
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 438
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 442
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY) 444
E-9 KICK-DOWN SWITCH DOES NOT WORK 446
E-10 BOOM KICK-OUT CANNOT BE USED 448
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION 452
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP 455
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP 455
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF 455
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 455
E-16 ABNORMALITY IN BUZZER 455
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE) 457
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS 459
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR 460
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED 464
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED 465
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED 466
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END) IS DISPLAYED 467
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END) IS DISPLAYED 468
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED 469
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED 470
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DISPLAYED 471
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE 472
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM 473
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 474
J-12 DISCONNECTION IN STEERING LEFT SOLENOID 475
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 477
M-1 MAIN MONITOR DOES NOT WORK 479
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP 480
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 481
M-4 ABNORMALITY IN SHIFT INDICATOR 482
M-5 HIGH BEAM DOES NOT LIGHT UP 484
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 485
M-7 ABNORMALITY IN PARKING DISPLAY 486
M-8 NOT USED 487
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 488
M-10 ABNORMALITY IN FRONT WORKING LAMP 490
M-11 ABNORMALITY IN REAR WORKING LAMP 492
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 494
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 496
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED 498
M-15 ABNORMALITY IN BUZZER 499
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 500
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 501
M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER 502
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY 503
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY 504
M-21 NOT USED 505
M-22 ABNORMALITY IN ECSS SYSTEM 506
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) 507
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE) 509
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS 512
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 514
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP LAMP RELAY) IS DISPLAYED 520
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED 522
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED 524
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED 526
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED 528
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED 530
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED 532
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 534
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 536
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED 540
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED 544
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 546
T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED 548
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE SYSTEM) IS DISPLAYED 549
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL SWITCH SYSTEM) IS DISPLAYED 550
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM) IS DISPLAYED 551
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM) IS DISPLAYED 552
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM) IS DISPLAYED 553
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM) IS DISPLAYED 554
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED 555
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM) IS DISPLAYED 556
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED 558
T-23 HOLD SWITCH SYSTEM 561
T-24 KICK-DOWN SWITCH SYSTEM 562
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM 563
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM 564
T-27 BUZZER SIGNAL SYSTEM 565
T-28 NETWORK SYSTEM 566
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM 567
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 568
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM 569
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM 570
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM 571
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM 572
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM 573
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM 574
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM 575
TROUBLESHOOTING AIR CONDITIONING (DENSO) 577
AIR CONDITIONER / HEATER (DENSO) 578
TROUBLESHOOTING THE ELECTRICAL CIRCUIT 582
ERROR MESSAGE TABLES 590
WIRING DIAGRAM 594
30 DISASSEMBLY AND ASSEMBLY 597
METHOD OF USING MANUAL 601
PRECAUTIONS DURING OPERATION 602
SPECIAL TOOL LIST 605
SKETCHES OF SPECIAL TOOLS 609
ENGINE 612
RADIATOR 614
DAMPER 616
TORQUE CONVERTER AND TRANSMISSION 626
TORQUE CONVERTER 631
TRANSMISSION 642
TRANSFER 676
PARKING BRAKE 685
TRANSMISSION CONTROL VALVE (ECMV) 692
CENTER SUPPORT 693
DRIVE SHAFT 700
FRONT AXLE 706
REAR AXLE 708
DIFFERENTIAL, NORMAL – (STANDARD) 714
FINAL DRIVE 731
ORBITAL STEERING VALVE 738
STEERING CYLINDER 751
STEERING VALVE 757
BRAKE VALVE 760
SLACK ADJUSTER 762
BRAKE ASSEMBLY (FRONT AND REAR) 765
HYDRAULIC PUMP 774
HYDRAULIC TANK 776
HYDRAULIC FILTER 778
PPC VALVE 779
MAIN CONTROL VALVE 781
BUCKET CYLINDER 791
BOOM CYLINDER 798
CENTER HINGE PIN 805
WORK EQUIPMENT 814
BULKHEAD 820
ENGINE HOOD 822
CAB 823
FLOOR FRAME 826
COUNTERWEIGHT 829
FUEL TANK 830
AIR CONDITIONER UNIT 832
CONDENSER 834
RECEIVER TANK 835
COMPRESSOR ASSEMBLY 836
MAIN MONITOR 837
40 MAINTENANCE STANDARD 839
ENGINE MOUNT 840
TRANSMISSION MOUNT 842
TORQUE CONVERTER CHARGING PUMP 844
DAMPER 846
TORQUE CONVERTER AND PTO 848
TRANSMISSION 851
TRANSFER 856
MAIN RELIEF, T C RELIEF VALVE 860
LUBRICATION RELIEF VALVE 862
DRIVE SHAFT 864
CENTER SUPPORT 866
DIFFERENTIAL, NORMAL – (STANDARD) 868
FINAL DRIVE 872
AXLE MOUNT 874
CENTER HINGE PIN 876
STEERING COLUMN 880
STEERING PUMP 882
STEERING VALVE 883
STEERING CYLINDER MOUNT 884
BRAKE VALVE 886
SLACK ADJUSTER 890
BRAKE 892
PARKING BRAKE 894
HYDRAULIC PUMP 896
SWITCH, PPC PUMP 898
PPC VALVE 900
CUT-OFF VALVE 902
MAIN CONTROL VALVE 904
HYDRAULIC CYLINDERS 910
BUCKET LINKAGE 914
BUCKET 917
BUCKET POSITIONER AND BOOM KICK-OUT 918
ROPS CAB 919
90 OTHERS 921
TRANSMISSION CUTAWAY 923
ELECTRIACL DIAGRAMS 925
ECSS WIRING DIAGRAM 925
JOYSTICK STEERING WIRING DIAGRAM 927
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 1 of 5) 929
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 2 of 5) 931
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 3 of 5) 933
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 4 of 5) 935
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 5 of 5) 937
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 1 of 4) 939
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 2 of 4) 941
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 3 of 4) 943
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 4 of 4) 945
ENGINE FLOOR HARNESS DIAGRAM 947
CAB ELECTRICAL DIAGRAM 949
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 1 OF 5) 951
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 2 OF 5) 953
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 3 OF 5) 955
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 4 OF 5) 957
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 5 OF 5) 959
3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 1 OF 2) 961
3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 2 OF 2) 963
PARKING BRAKE CONTROL DIAGRAM 965
HYDRAULIC 967
CIRCUIT DIAGRAM 967
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) 969
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3) 971
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3) 973
STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) 975
STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3) 977
STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3) 979
HYDRAULIC LINE ASSEMBLY (PART 1 OF 3) 981
HYDRAULIC LINE ASSEMBLY (PART 2 OF 3) 983
HYDRAULIC LINE ASSEMBLY (PART 3 OF 3) 985

DESCRIPTION:

Komatsu WA500-3H Wheel Loader Shop Manual VEBM500100 – PDF DOWNLOAD 

SERIAL NUMBER WA500H20051 and up

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24