Komatsu WA500-3 Wheel Loader Shop Manual SEBM009016 – PDF DOWNLOAD

Komatsu WA500-3 Wheel Loader Shop Manual SEBM009016 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-3 Wheel Loader Shop Manual SEBM009016 – PDF DOWNLOAD

Language : English
Pages : 1374
Downloadable : Yes
File Type : PDF
Size: 43.7 MB

TABLE OF CONTENTS:

Komatsu WA500-3 Wheel Loader Shop Manual SEBM009016 – PDF DOWNLOAD

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
SAFETY 9
SAFETY NOTICE 9
FOREWORD 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
ELECTRIC WIRE CODE 21
CONVERSION TABLE 22
UNITS 28
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 33
WEIGHT TABLE 36
LIST OF LUBRICANT AND WATER 37
10 STRUCTURE AND FUNCTION 41
GENERAL 42
RADIATOR AND OIL COOLER 44
DAMPER 49
TORQUE CONVERTER AND TRANSMISSION PIPING 51
HYDRAULIC CIRCUIT FOR POWER TRAIN 54
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 55
TORQUE CONVERTER AND PTO 56
TRANSMISSION 58
TRANSMISSION CONTROL VALVE 72
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 74
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE 80
LUBRICATING RELIEF VALVE 82
TORQUE CONVERTER OIL FILTER 83
PILOT FILTER 84
TRANSFER 85
DRIVE SHAFT 86
CENTER SUPPORT 87
AXLE 88
DIFFERENTIAL 90
LIMITED SLIP DIFFERENTIAL 93
FINAL DRIVE 98
AXLE MOUNT 100
CENTER HINGE PIN 102
STEERING PIPING 103
STEERING COLUMN 104
STEERING VALVE 105
ORBIT-ROLL VALVE 119
STOP VALVE 123
DIVERTER VALVE 124
BRAKE PIPING 127
BRAKE CIRCUIT DIAGRAM 130
BRAKE VALVE 133
CHARGE VALVE 138
ACCUMULATOR (FOR BRAKE) 142
SLACK ADJUSTER 143
BRAKE 146
PARKING BRAKE CONTROL 148
PARKING BRAKE 149
PARKING BRAKE SOLENOID VALVE 150
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE 151
HYDRAULIC PIPING 152
HYDRAULIC CIRCUIT SYSTEM 154
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 156
WORK EQUIPMENT LEVER LINKAGE 158
HYDRAULIC TANK 159
ACCUMULATOR (FOR PPC VALVE) 162
PPC VALVE 164
PPC RELIEF VALVE 171
CUT-OFF VALVE 172
E C S S CONTROL VALVE 176
MAIN CONTROL VALVE 178
WORK EQUIPMENT LINKAGE 192
BUCKET 194
BUCKET POSITIONER AND BOOM KICK-OUT 195
OPERATION OF PROXIMITY SWITCH 199
CAB 203
ROPS CANOPY 206
AIR CONDITIONER 209
ELECTRIC CIRCUIT DIAGRAM 214
MACHINE MONITOR SYSTEM 222
MAIN MONITOR 225
MAINTENANCE MONITOR 230
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM 233
JOYSTICK TRANSMISSION SYSTEM 243
E C S S (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) 244
TRANSMISSION AND E C S S CONTROLLER 252
WORK EQUIPMENT CONTROL SYSTEM 254
REMOTE POSITION, JOYSTICK STEERING CONTROLLER 259
SENSORS 260
ENGINE STARTING CIRCUIT 265
ENGINE STOP CIRCUIT 267
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM) 269
ELECTRIC TRANSMISSION CONTROL 272
KICK-DOWN, HOLD SWITCH 275
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAM 276
ELECTRIC PARKING BRAKE CONTROL 279
20 TESTING AND ADJUSTING 291
STANDARD VALUE TABLE FOR ENGINE 292
STANDARD VALUE TABLE FOR CHASSIS 294
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS 304
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 329
SKETCHES OF SPECIAL TOOLS 332
MEASURING ENGINE SPEED 333
MEASURING EXHAUST GAS COLOR 335
ADJUSTING VALVE CLEARANCE 336
MEASURING COMPRESSION PRESSURE 338
MEASURING BLOW-BY PRESSURE 341
MEASURING ENGINE OIL PRESSURE 342
HANDLING EQUIPMENT IN FUEL SYSTEM 344
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 344
CHECK FOR LEAKAGE IN FUEL SYSTEM 345
BLEEDING AIR FROM FUEL SYSTEM 346
MEASURING FUEL PRESSURE 348
TESTING AND ADJUSTING FUEL INJECTION TIMING 349
REDUCED CYLINDER MODE OPERATION 350
METHOD OF REDUCED CYLINDER MODE OPERATION 351
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 353
TESTING AND ADJUSTING FAN BELT TENSION 354
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 355
MEASURING EXHAUST TEMPERATURE 357
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 359
ADJUSTING SPEED SENSOR 361
ADJUSTING FUEL CONTROL CABLE 363
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 364
TESTING AND ADJUSTING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE 366
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT 369
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS 370
TESTING AND ADJUSTING STEERING OIL PRESSURE 372
TESTING AND ADJUSTING STEERING STOP VALVE 374
TESTING BRAKE OIL PRESSURE 375
MEASURING BRAKE DISC WEAR 376
MEASURING BRAKE PERFORMANCE 377
MEASURING PARKING BRAKE OIL PRESSURE 378
TESTING WEAR OF PARKING BRAKE DISC 380
MANUAL RELEASE METHOD FOR PARKING BRAKE 381
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 382
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS 384
TESTING AND ADJUSTING PPC OIL PRESSURE 396
ADJUSTING PPC VALVE LINKAGE 400
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 401
ADJUSTING WORK EQUIPMENT LEVER LINKAGE 403
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT 404
INITIAL TEACHING METHOD FOR TRANSMISSION CONTROLLER 405
TESTING AND ADJUSTING OF BUCKET POSITIONER 407
TESTING AND ADJUSTING OF BOOM KICK-OUT 409
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 411
BLEEDING AIR 413
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 414
TROUBLESHOOTING 415
POINTS TO REMEMBER WHEN TROUBLESHOOTING 416
SEQUENCE OF EVENTS IN TROUBLESHOOTING 417
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 418
CHECKS BEFORE TROUBLESHOOTING 426
CONNECTOR TYPES AND MOUNTING LOCATIONS 427
CONNECTOR ARRANGEMENT DIAGRAM 436
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 438
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM 458
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 478
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENATION 480
TRANSMISSION CONTROLLER LED DISPLAY 490
METHOD OF USING JUDGEMENT TABLE 491
METHOD OF USING TROUBLESHOOTING CHARTS 492
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 494
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (Serial No : 50001 – 52000) 497
METHOD OF USING TROUBLESHOOTING CHARTS 498
S-1 Starting performance is poor (Starting always takes time) 502
S-2 Engine does not start 504
(1) Engine does not turn 504
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) 505
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) 506
S-3 Engine does not pick up smoothly (Follow-up is poor) 507
S-4 Engine stops during operations 508
S-5 Engine does not rotate smoothly (Hunting) 509
S-6 Engine lacks output (or lacks power) 510
S-7 Exhaust smoke is black (Incomplete combustion) 511
S-8 Oil consumption is excessive (or exhaust smoke is blue) 512
S-9 Oil becomes contaminated quickly 513
S-10 Fuel consumption is excessive 514
S-11 Oil is in cooling water, or water spurts back, or water level goes down 515
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) 516
S-13 Oil level rises (Water, fuel in oil) 517
S-14 Water temperature becomes too high (Overheating) 518
S-15 Abnormal noise is made 519
S-16 Vibration is excessive 520
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (Serial No : 52001 and up) 521
METHOD OF USING TROUBLESHOOTING CHARTS 523
S-1 Starting performance is poor (starting always takes time) 526
S-2 Engine does not start 527
a) Engine does not turn 527
b) Engine turns but no exhaust smoke comes out 528
c) Exhaust smoke comes out but engine does not start (Fuel is being injected) 529
S-3 Engine does not pick up smoothly (follow-up is poor) 530
S-4 Engine stops during operations 531
S-5 Engine does not rotate smoothly (hunting) 532
S-6 Engine lacks output (or lacks power) 533
S-7 Exhaust smoke is black (incomplete combustion) 534
S-8 Oil consumption is excessive (or exhaust smoke is blue) 535
S-9 Oil becomes contaminated quickly 536
S-10 Fuel consumption is excessive 537
S-11 Oil is in cooling water (or water spurts back, or water level goes down) 538
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 539
S-13 Oil level rises (water, fuel in oil) 540
S-14 Water temperature becomes too high (overheating) 541
S-15 Abnormal noise is made 542
S-16 Vibration is excessive 543
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE) 545
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS 546
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 548
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM 556
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed 560
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed 561
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed 562
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed 563
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed 564
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed 565
T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed 566
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed 567
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed 568
T-10 Failure code [21] (Short circuit, disconnection in range switch system) is displayed 572
T-11 Failure code [22] (Disconnection in travel speed sensor system) is displayed 575
T-12 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed 576
T-13 Failure code [24] (Short circuit, disconnection in EEP ROM) is displayed 579
T-14 Failure code [25] (Short circuit in transmission oil temperature system) is displayed 580
T-15 Failure code [26] (Short circuit in F ECMV fill switch system) is displayed 581
T-16 Failure code [27] (Short circuit in R ECMV fill switch system) is displayed 581
T-17 Failure code [28] (Short circuit in 1st ECMV fill switch system) is displayed 582
T-18 Failure code [29] (Short circuit in 2nd ECMV fill switch system) is displayed 582
T-19 Failure code [30] (Short circuit in 3rd ECMV fill switch system) is displayed 583
T-20 Failure code [31] (Short circuit in 4th ECMV fill switch system) is displayed 583
T-21 Failure code [32] (Short circuit in F or R ECMV fill switch system) is displayed 584
T-22 Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill switch system) is displayed 586
T-23 Hold switch system 588
T-24 Kick-down switch system 588
T-25 Transmission cut-off signal system 589
T-26 Neutralizer relay signal system 590
T-27 Buzzer signal system 593
T-28 Network system 594
T-29 Transmission controller power source system 595
T-30 Short circuit in travel speed sensor system 596
T-31 Disconnection in transmission oil temperature sensor system 597
T-32 Disconnection in F ECMV fill switch system 598
T-33 Disconnection in R ECMV fill switch system 598
T-34 Disconnection in 1st ECMV fill switch system 599
T-35 Disconnection in 2nd ECMV fill switch system 599
T-36 Disconnection in 3rd ECMV fill switch system 600
T-37 Disconnection in 4th ECMV fill switch system 600
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 601
TROUBLE DATA DISPLAY 605
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM 612
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM 616
ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND HAZARD SYSTEM 617
M-1 Main monitor does not work 618
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up 619
M-3 Speedometer display does not work properly 622
M-4 Abnormality in shift indicator 623
a) Displays N even when directional lever is at F 623
b) Displays N even when directional lever is at R 623
c) Does not display N even when directional lever is at N, and displays R when directional lever is at F 623
d) Does not display N even when directional lever is at N, and displays F when directional lever is at R 624
e) Does not display 1st – 4th 624
M-5 High beam does not light up 625
M-6 Turn signal display does not light up 626
a) L H turn signal display does not light up 626
b) R H turn signal display does not light up 626
M-7 Abnormality in parking display 627
a) Parking lamp display does not light up 627
b) Parking lamp display stays lighted up 627
M-8 Abnormality in preheating system 628
(1) Abnormality in preheating system (QHS) 628
a) Does not carry out preheating 628
b) Always carries out preheating for 45 seconds 629
c) Preheating stays on 629
d) Preheating time becomes shorter, or there is variation 630
(2) Abnormality in preheating system 631
a) Does not carry out preheating 631
b) Preheating stays on 631
M-9 Night lighting does not light up 633
M-10 Abnormality in front working lamp 634
a) Neither monitor display nor front working lamp light up 634
b) Working lamp lights up but monitor display does not light up 634
c) Monitor display lights up but working lamp does not light up 634
M-11 Abnormality in rear working lamp 636
a) Neither monitor display nor rear working lamp light up 636
b) Working lamp lights up but monitor display does not light up 636
c) Monitor display lights up but working lamp does not light up 636
M-12 Abnormality in transmission cut-off 638
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change 638
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off function is actuated when pedal is depressed 638
c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated 638
d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF) 638
e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated 639
M-13 Abnormality in parking brake dragging warning 640
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when directional lever is at N 640
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at position other than N 640
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated 644
a) Actuated continuously 644
b) Not actuated 644
M-15 Abnormality in buzzer 645
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) 645
b) Buzzer always sounds 645
M-16 Condition of monitor switches is not stored in memory 646
M-17 Abnormality in failure display mode 648
a) Does not enter failure display mode 648
b) Count for time elapsed since failure in failure display mode does not advance 648
M-18 Buzzer is not made to sound by transmission controller 650
M-19 Abnormality in emergency steering normal display 651
a) Emergency steering normal display does not light up 651
b) Emergency steering normal display stays lighted up 651
M-20 Abnormality in emergency steering actuation display 652
a) Emergency steering actuation display does not light up 652
b) Emergency steering actuation display stays lighted up 652
M-21 Abnormality in auto-greasing system 653
a) Forced greasing cannot be carried out 653
b) Monitor display flashes rapidly (2 times/sec) 653
c) When no more grease remains, monitor display flashes rapidly (2 times/sec) 653
d) Monitor display flashes slowly (1 time/sec) 654
e) Monitor display goes out 654
M-22 Abnormality in ECSS system 655
a) Display does not change when switch is pressed 655
b) Monitor display lights up but ECSS function does not work 655
c) Display does not light up 655
M-23 Failure code is not sent to main monitor (abnormality in network) 656
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 657
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM 658
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does not work 662
a) No lamps on maintenance monitor light up 662
b) Some lamps do not light up 663
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds) 665
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out 667
K-4 When starting switch is turned ON (engine stopped), CHECK items flash 668
a) Engine oil level display flashes 668
b) Engine water level display flashes 670
K-5 When starting switch is turned ON (engine started), CAUTION items flash 672
a) Engine oil pressure display flashes 672
b) Battery charge level display flashes 674
c) Brake oil pressure display flashes 676
d) Air cleaner display flashes 677
K-6 CAUTION items are flashing but caution buzzer does not sound 679
K-7 There is no abnormality in monitor display but caution buzzer sounds 680
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash 681
a) CHECK lamp 681
b) CAUTION lamp 681
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up 682
a) CHECK lamp 682
b) CAUTION lamp 682
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) 683
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up 684
K-12 Service meter does not work 685
K-13 Service meter is running even when engine is stopped 687
K-14 Abnormality in gauge items 689
a) Abnormality in fuel gauge 689
b) Abnormality in engine water temperature gauge 691
c) Abnormality in torque converter oil temperature gauge 693
K-15 Maintenance monitor check 695
a) Check switch system 695
b) Check LED system 695
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 697
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING・STOP AND PREHEATING SYSTEM 698
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM 701
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM 704
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER SYSTEM 705
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM 706
E-1 Engine does not start 710
a) Starting motor does not turn 710
b) Starting motor turns 722
E-2 Engine does not stop 724
E-3 Engine stops when machine is traveling 724
E-4 Abnormality in preheating system (QHS) 726
a) Does not carry out preheating 726
b) Always carries out preheating for 45 seconds 727
c) Preheating stays on 727
d) Preheating time becomes shorter, or there is variation 728
E-5 Parking brake does not have effect 729
a) Parking brake has no effect when parking brake switch is turned ON (actuated) 729
b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake) 729
E-6 Parking brake is applied when machine is traveling 730
E-7 Parking brake is released when starting switch is turned ON 734
E-8 Transmission does not change to neutral when parking brake is applied (but parking brake works normally) 734
E-9 Kick-down switch does not work 738
a) Kick-down switch does not work (shift works correctly during normal gear shift operations) 738
b) Kick-down is not canceled 739
E-10 Boom kick-out cannot be used 740
E-11 Abnormality in bucket positioner function 744
E-12 Abnormality in lighting up of front working lamp 747
E-13 Abnormality in lighting up of rear working lamp 747
E-14 Abnormality in transmission cut-off 747
E-15 Abnormality in parking brake dragging warning 747
E-16 Abnormality in buzzer 747
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 749
H-1 Machine does not start 750
H-2 Travel speed is slow, thrusting power is weak, lacks power on slopes, does not shift gear 754
H-3 Excessive shock when starting machine or shifting gear 757
H-4 Excessive time lag when starting machine or shifting gear 759
H-5 Torque converter oil temperature is high 761
H-6 Steering does not turn 762
H-7 Steering does not turn [machine with joystick] 763
H-8 Turning, response of steering is poor 764
H-9 Turning, response of steering is poor [machine with joystick] 766
H-10 Steering is heavy 768
H-11 Joystick is heavy [machine with joystick] 768
H-12 Steering wheel shakes or jerks 769
H-13 Steering shakes or there is excessive shock [machine with joystick] 770
H-14 Turning radius is different between left and right at maximum steering 770
H-15 Wheel brakes do not work or braking effect is poor 772
H-16 Wheel brakes are not released or brakes drag 774
H-17 Parking brake does not work or braking effect is poor 775
H-18 Parking brake is not released or brake drags (including emergency release system) 776
H-19 Neither boom nor bucket move 777
H-20 Both boom and bucket are slow or lack power 778
H-21 Boom does not move 779
H-22 Boom does not move [machines with remote boom control] 780
H-23 Boom is slow or boom lacks power 781
H-24 Boom is slow or boom lacks power [machines with remote boom control] 782
H-25 Boom cannot be set to FLOAT or cannot be released from FLOAT 783
H-26 Boom drops momentarily when control lever is operated from HOLD to RAISE 783
H-27 Remote boom control does not work [machines with remote boom control] 784
H-28 Excessive hydraulic drift of boom 785
H-29 Bucket does not move 786
H-30 Bucket is slow or lacks power 787
H-31 Excessive hydraulic drift of bucket 788
H-32 ECSS does not work, and there is pitching and bouncing [machines with ECSS] 789
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) 791
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM 792
Electrical circuit diagram for ECSS 796
D-1 ECSS does not work 798
a) Error code [d0] is displayed 800
b) Error code [d1] is displayed 800
c) Error code [d2] is displayed 801
d) Error code [d3] is displayed 801
e) No abnormality display is given 803
D-2 ECSS cannot be canceled 806
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE) 807
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS 808
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 810
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM 814
J-1 Failure code [56] (Short circuit, disconnection in caution relay output) is displayed 816
J-2 Failure code [57] (Short circuit in steering right solenoid (detected when output)) is displayed 818
J-3 Failure code [58] (Short circuit in steering left solenoid (detected when output)) is displayed 819
J-4 Failure code [59] (Short circuit in steering right solenoid (HOT end)) is displayed 820
J-5 Failure code [60] (Short circuit in steering left solenoid (HOT end)) is displayed 821
J-6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay output) is displayed 822
J-7 Failure code [62] (Short circuit, disconnection in joystick steering neutral signal) is displayed 823
J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever potentiometer system) is displayed 824
J-9 Abnormality in power source, voltage 825
J-10 Abnormality in joystick steering ON-OFF signal system 826
J-11 Disconnection in steering right solenoid 827
J-12 Disconnection in steering left solenoid 828
TROUBLESHOOTING OF REMOTE BOOM POSITIONER CONTROLLER SYSTEM (W MODE) 829
JUDGEMENT TABLE FOR REMOTE BOOM POSITIONER CONTROLLER SYSTEM RELATED PARTS 830
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 832
ELECTRICAL CIRCUIT DIAGRAM FOR REMOTE BOOM POSITIONER SYSTEM 834
W-1 Failure code [43] (Short circuit, disconnection in damping solenoid system) is displayed 837
W-2 Failure code [44] (Short circuit in power source at hot end of damping solenoid) is displayed 838
W-3 Failure code [45] (Short circuit in power source at return end of damping solenoid) is displayed 838
W-4 Failure code [49] (Short circuit, disconnection in boom lever kick-out relay system) is displayed 839
W-5 Failure code [51] (Disconnection in boom RAISE, LOWER detection pressure switch) is displayed 840
W-6 Failure code [52] (Short circuit, disconnection in boom angle potentiometer system) is displayed 841
W-7 Sensor cannot be adjusted 842
W-8 Abnormality in engine speed signal system 842
W-9 Remote positioner RAISE, LOWER LEDs do not light up 845
a) Remote positioner switch system 845
b) Remote positioner LED system 845
W-10 Remote positioner RAISE set LED does not flash 846
a) Remote positioner RAISE set switch system 846
b) Remote positioner RAISE set LED system 846
W-11 Remote positioner LOWER set LED does not flash 847
a) Remote positioner LOWER set switch system 847
b) Remote positioner LOWER set LED system 847
W-12 Buzzer for switch operation does not sound 848
W-13 Shock when stopping boom (abnormality in boom lever detent switch) 849
W-14 Short circuit in boom RAISE, LOWER pressure detection switch 850
TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM (C MODE) 851
ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM 854
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM 856
C-1 When engine is running, engine oil level display shows “Abnormal” 858
C-2 When engine is running, battery electrolyte level display shows “Abnormal” 859
C-3 Abnormality in engine water level display 860
a) Display shows “Abnormal” 860
b) Display shows “Disconnection” 860
c) Display shows “Short circuit” 860
C-4 Abnormality in brake oil pressure display 862
a) When engine is running, display shows “Abnormal” 862
b) Display shows “Disconnection” 863
c) Display shows “Short circuit” 863
C-5 Abnormality in engine oil pressure display 864
a) When engine is running, display shows “Abnormal” 864
b) When engine is stopped or running, display shows “Disconnection” 864
c) Only when engine is stopped, display shows “Disconnection” 864
d) Display shows “Short circuit” 865
C-6 When starting switch is at ON (engine started), battery charge display shows “Abnormal” 866
C-7 When starting switch is at ON (engine started), air cleaner display shows “Abnormal” 867
C-8 CAUTION item display shows “Abnormal”, but alarm buzzer does not sound 868
C-9 Monitor display does not show “Abnormal”, but alarm buzzer sounds 869
C-10 CAUTION item display shows “Abnormal”, but warning lamp (CHECK lamp, CAUTION lamp) does not flash 870
a) CHECK lamp 870
b) CAUTION lamp 870
C-11 Monitor display does not show any abnormality, but warning lamp (CHECK lamp, CAUTION lamp) lights up 871
a) CHECK lamp 871
b) CAUTION lamp 871
C-12 Service meter does not work 872
C-13 Service meter is running when engine is stopped 872
C-14 Abnormality in fuel gauge 873
a) Display shows “Disconnection” or low fuel level 873
b) Display always shows FULL and does not go down 873
C-15 Abnormality in engine water temperature gauge 874
a) Display shows “Short circuit” 874
b) Display always shows lowest level and does not go up 874
C-16 Abnormality in torque converter oil temperature gauge 875
a) Display shows “Short circuit” 875
b) Display always shows lowest level and does not go up 875
C-17 When starting switch is turned to ON, monitor is not actuated (KOMATSU is not displayed) 876
a) Main monitor CHECK lamps do not light up 876
b) Main monitor CHECK lamps light up 877
C-18 Does not switch to working memory (engine running) mode, or switches to check before starting mode when engine is running 878
C-19 Abnormality in MDC monitor display 879
a) Display color is abnormal 879
b) Display flickers 879
C-20 Even when switch is operated, nothing functions 880
C-21 Does not switch to TV/video mode 882
a) Stays at PARKING BRAKE APPLIED display 882
b) Display does not light up 884
C-22 Abnormality in memory data 886
a) Load meter data is not saved to memory 886
b) Maintenance time is not saved to memory 886
C-23 Engine speed stays at 0 rpm 887
C-24 Pressure sensor display shows “Disconnection” 888
a) Sensor power source display also shows “Abnormal” 888
b) Only pressure sensor display shows “Disconnection” 888
C-25 Load meter cannot weigh load 889
a) Cannot carry out calibration 889
b) Can carry out calibration 890
C-26 Abnormality in lever switch 891
a) Sub-total switch does not work 891
b) Cancel switch does not work 891
C-27 Printer does not print out 892
C-28 Abnormality in antenna system 893
C-29 Abnormality in speaker system 894
a) Abnormality in right speaker 894
b) Abnormality in left speaker 894
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE) 895
TABLE OF ERROR CODES 897
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED 898
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING 906
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM 910
ENG-1 Error code E-1b [Abnormality in Ne speed sensor system] 913
ENG-2 Error code E-1c [Abnormality in G speed sensor system] 914
ENG-3 Error code E-22 [Overrun] 915
ENG-4 Error code E-31 [Abnormality in throttle sensor system] 916
ENG-5 Error code E-3c [Abnormality in boost pressure sensor system] 918
ENG-6 Error code E-3d [Abnormality in fuel temperature sensor system] 921
ENG-7 Error code E-51 [Abnormality in preheater relay coil system] 922
ENG-8 Error code E-54 [Short circuit in starting switch C signal system] 923
ENG-9 Error code E-56 [Abnormality in power supply system 1] 924
ENG-10 Error code E-57 [Abnormality in power supply system 2] 925
ENG-11 Error code E-5A [Abnormality in Q adjustment switch signal] 926
ENG-12 Error code E-6A [Abnormality in low water temperature sensor system] 927
ENG-13 Error code E-70 [Overcurrent in fuel supply pump PCV1 system] 928
ENG-14 Error code E-71 [Overcurrent in fuel supply pump PCV2 system] 929
ENG-15 Error code E-74 [Disconnection in fuel supply pump PCV1 system] 930
ENG-16 Error code E-75 [Disconnection in fuel supply pump PCV2 system] 931
ENG-17 Error code E-77 [Abnormality in common rail fuel pressure sensor system] 932
ENG-18 Error code E-79 [Abnormality in high common rail fuel pressure 1]　Error code E-7A [Abnormality in high common rail fuel pressure 2] 936
ENG-19 Error code E-7b [No-pressure feed by fuel supply pump 1]　Error code E-7c [No-pressure feed by fuel supply pump 2] 938
ENG-20 Error code E-7d [Abnormality in common rail high fuel pressure] 941
ENG-21 Error code E-80 [Defective controller] 942
ENG-22 Error code E-81 [Disconnection in No 1 fuel injector system] 943
ENG-23 Error code E-82 [Disconnection in No 2 fuel injector system] 944
ENG-24 Error code E-83 [Disconnection in No 3 fuel injector system] 945
ENG-25 Error code E-84 [Disconnection in No 4 fuel injector system] 946
ENG-26 Error code E-85 [Disconnection in No 5 fuel injector system] 947
ENG-27 Error code E-86 [Disconnection in No 6 fuel injector system] 948
ENG-28 Error code E-8A [Short circuit in No 1, No 2, No 3 fuel injector systems] 949
ENG-29 Error code E-8b [Short circuit in No 4, No 5, No 6 fuel injector systems] 950
30 DISASSEMBLY AND ASSEMBLY 951
METHOD OF USING MANUAL 953
PRECAUTIONS WHEN CARRYING OUT OPERATION 954
SPECIAL TOOL LIST 956
SKETCHES OF SPECIAL TOOLS 962
STARTING MOTOR 965
Removal and Installation 965
ALTERNATOR 966
Removal and Installation (Serial No : 50001 – 52000) 966
Removal and Installation (Serial No : 52001 and up) 967
ENGINE OIL COOLER 968
Removal 968
Installation 969
FUEL INJECTION PUMP 970
Removal and Installation 970
FUEL SUPPLY PUMP 971
Removal 971
Installation 973
WATER PUMP 974
Removal 974
Installation 975
NOZZLE HOLDER 976
Removal and Installation 976
FUEL INJECTOR 977
Removal 977
Installation 979
TURBOCHARGER 981
Removal 981
Installation 982
ENGINE FRONT SEAL 984
Removal and Installation 984
ENGINE REAR SEAL 985
Removal 985
Installation 986
CYLINDER HEAD 988
Removal 988
Installation 996
RADIATOR 1001
Removal 1001
Installation 1004
ENGINE 1005
Removal 1005
Installation 1013
DAMPER 1014
Removal and Installation 1014
Disassembly 1015
Assembly 1018
TORQUE CONVERTER, TRANSMISSION 1023
Removal 1023
Installation 1025
Disconnection 1026
Connection 1027
TORQUE CONVERTER 1028
Disassembly 1028
Assembly 1032
TRANSMISSION 1039
Disassembly 1039
Assembly 1056
TRANSFER 1073
Disassembly 1073
Assembly 1077
PARKING BRAKE 1082
Disassembly 1082
Assembly 1085
TRANSMISSION CONTROL VALVE 1090
Removal and Installation 1090
CENTER SUPPORT 1091
Removal 1091
Installation 1092
Disassembly 1093
Assembly 1095
DRIVE SHAFT 1098
Disassembly 1098
Assembly 1101
FRONT AXLE 1104
Removal 1104
Installation 1105
FRONT DIFFERENTIAL 1106
Removal 1106
Installation 1108
REAR AXLE 1109
Removal 1109
Installation 1114
REAR DIFFERENTIAL 1115
Removal 1115
Installation 1116
DIFFERENTIAL GEAR 1117
Disassembly 1117
Assembly 1121
LIMITED SLIP DEFFERENTIAL 1129
Disassembly 1129
Assembly 1133
FINAL DRIVE AND BRAKE 1143
Disassembly 1143
Assembly 1150
ORBIT-ROLL 1162
Removal and Installation 1162
Disassembly 1163
Assembly 1168
STEERING CYLINDER 1175
Removal 1175
Installation 1176
Disassembly 1177
Assembly 1179
STEERING VALVE 1181
Removal 1181
Installation 1183
BRAKE VALVE 1184
Removal 1184
Installation 1185
SLACK ADJUSTER 1186
Removal and Installation 1186
Disassembly 1187
Assembly 1188
ACCUMULATOR CHARGE VALVE 1189
Removal 1189
Installation 1190
Disassembly 1192
Assembly 1194
HYDRAULIC PUMP 1197
Removal 1197
Installation 1198
HYDRAULIC TANK 1199
Removal 1199
Installation 1200
HYDRAULIC FILTER 1201
Removal and Installation 1201
PPC VALVE 1202
Removal and Installation 1202
Disassembly and Assembly 1203
MAIN CONTROL VALVE 1204
Removal 1204
Installation 1206
Disassembly 1208
Assembly 1212
BUCKET CYLINDER 1215
Removal 1215
Installation 1216
BOOM CYLINDER 1217
Removal 1217
Installation 1218
BOOM AND BUCKET CYLINDERS 1219
Disassembly 1219
Assembly 1221
CENTER HINGE PIN 1224
Removal 1224
Installation 1230
WORK EQUIPMENT 1233
Removal 1233
Installation 1237
BULKHEAD 1238
Removal 1238
Installation 1242
ENGINE HOOD 1243
Removal 1243
Installation 1244
FLOOR FRAME 1245
Removal 1245
Installation 1250
COUNTERWEIGHT 1251
Removal and Installation 1251
FUEL TANK 1252
Removal 1252
Installation 1255
CAB 1256
Removal 1256
Installation 1258
AIR CONDITIONER UNIT 1259
Removal 1259
Installation 1260
AIR CONDITIONER CONDENSOR 1261
Removal 1261
Installation 1262
RECEIVER TANK 1263
Removal 1263
Installation 1264
AIR CONDITIONER COMPRESSOR 1265
Removal 1265
Installation 1266
40 MAINTENANCE STANDARD 1267
ENGINE MOUNT 1268
TRANSMISSION MOUNT 1269
DAMPER 1270
TORQUE CONVERTER CHARGING PUMP 1271
TORQUE CONVERTER, PTO 1272
TRANSMISSION 1274
TRANSFER 1282
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE 1284
LUBRICATION RELIEF VALVE 1285
DRIVE SHAFT 1286
CENTER SUPPORT 1287
DIFFERENTIAL 1288
LIMITED SLIP DIFFERENTIAL 1292
FINAL DRIVE 1294
AXLE MOUNT 1296
CENTER HINGE PIN 1298
STEERING COLUMN 1300
STEERING PUMP 1301
STEERING VALVE 1303
STEERING CYLINDER MOUNT 1304
BRAKE VALVE 1306
SLACK ADJUSTER 1309
BRAKE 1310
PARKING BRAKE 1312
HYDRAULIC PUMP 1313
SWITCH, PPC PUMP 1314
PPC VALVE 1315
CUT-OFF VALVE 1317
MAIN CONTROL VALVE 1318
HYDRAULIC CYLINDERS 1322
BUCKET LINKAGE 1324
BUCKET 1326
BUCKET POSITIONER AND BOOM KICK-OUT 1327
ROPS CAB 1329
90 OTHERS 1331
TRANSMISSION 1333
BRAKE PIPING　SERIAL No : 50001 – 52000 1335
HYDRAULIC PIPING　SERIAL No : 50001 – 52000 1337
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM　Serial No : 50001 – 52000 1339
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH OPTIONAL SPECIFICATION)　Serial No : 50001 – 52000 1341
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM　Serial No : 52001 and up 1343
ELECTRIC CIRCUIT DIAGRAM (1/4)　Serial No : 50001 – 52000 1345
ELECTRIC CIRCUIT DIAGRAM (2/4)　Serial No : 50001 – 52000 1347
ELECTRIC CIRCUIT DIAGRAM (3/4)　Serial No : 50001 – 52000 1349
ELECTRIC CIRCUIT DIAGRAM (4/4)　Serial No : 50001 – 52000 1351
ELECTRIC CIRCUIT DIAGRAM (1/5)　Serial No : 52001 and up 1353
ELECTRIC CIRCUIT DIAGRAM (2/5)　Serial No : 52001 and up 1355
ELECTRIC CIRCUIT DIAGRAM (3/5)　Serial No : 52001 and up 1357
ELECTRIC CIRCUIT DIAGRAM (4/5)　Serial No : 52001 and up 1359
ELECTRIC CIRCUIT DIAGRAM (5/5)　Serial No : 52001 and up 1361
ELECTRIC PARKING BRAKE CONTROL 1363
CONNECTOR ARRANGEMENT DIAGRAM (1/2)　Serial No : 50001 – 52000 1365
CONNECTOR ARRANGEMENT DIAGRAM (2/2)　Serial No : 50001 – 52000 1367
CONNECTOR ARRANGEMENT DIAGRAM (1/2)　Serial No : 52001 and up 1370
CONNECTOR ARRANGEMENT DIAGRAM (2/2)　Serial No : 52001 and up 1372

DESCRIPTION:

Komatsu WA500-3 Wheel Loader Shop Manual SEBM009016 – PDF DOWNLOAD

MACHINE MODEL           SERIAL NUMBER

WA500-3                                50001 and up
WA500-3 avance                  50570 and up

FOREWORD;
GENERAL:

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY;
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

IMAGES PREVIEW OF THE MANUAL: