Komatsu WA500-3 Wheel Loader Service Repair Shop Manual (A70001-up) - CEBM001202

This complete service repair workshop manual PDF download for the WA500-3 Komatsu Wheel Loader (SN: A70001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : WA500-3LE
Serial Numbers : A70001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING, ADJUSTING, AND TROUBLESHOOTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHER


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM001202
Total Pages : 1046


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COVER
CONTENTS

01 GENERAL
DIMENSIONS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT, AND LUBRICANTS
ENGINE OIL SPECIFICATIONS
TRANSMISSION, HYDRAULIC, AND BRAKE OIL
AXLE OIL SPECIFICATIONS
GREASE SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
COOLANT SPECIFICATIONS

10 STRUCTURE AND FUNCTION
GENERAL
RADIATOR AND OIL COOLER
DAMPER
TORQUE CONVERTER AND TRANSMISSION PIPING
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
TORQUE CONVERTER AND PTO
TRANSMISSION
TRANSMISSION CONTROL VALVE
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
LUBRICATING RELIEF VALVE
TORQUE CONVERTER OIL FILTER
PILOT FILTER
TRANSFER
DRIVE SHAFT
CENTER SUPPORT
AXLE
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
TIRE AND WHEEL
STEERING PIPING
ELECTRIC PARKING BRAKE CONTROL
STEERING COLUMN
STEERING VALVE
ORBIT-ROLL VALVE
STOP VALVE
DIVERTER VALVE
BRAKE CIRCUIT DIAGRAM
BRAKE VALVE
CHARGE VALVE
ACCUMULATOR (FOR BRAKE)
SLACK ADJUSTER
BRAKE
PARKING BRAKE CONTROL
PARKING BRAKE
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
HYDRUALIC CIRCUIT SYSTEM
WORK EQUIPMENT LEVER LINKAGE
HYDRAULIC TANK
ACCUMULATOR (FOR PPC VALVE)
PPC VALVE
PPC RELIEF VALVE
CUT-OFF VALVE
MAIN CONTROL VALVE
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
PROXIMITY SWITCH
CAB
ROPS CANOPY
AIR CONDITIONER
AIR CONDITIONER PIPING
BASIC INFORMATION ON AIR CONDITIONERS
UNITS RELATED TO REFRIGERATION
PRINCIPLE OF COOLING
REFRIGERANTS
SAFETY PRECAUTIONS
REFRIGERATOR OIL (LUBE OIL)
AIR CONDITIONING CONDENSER
FUNCTION
GENERAL DESCRIPTION
AIR CONDITIONER COMPRESSOR
RECEIVER WITH SIGHT GLASS (LIQUID TANK)
AIR CONDITIONER UNIT
OUTLINE
ELECTRIC CIRCUIT DIAGRAM
MACHINE MONITOR SYSTEM
MAIN MONITOR
MAINTENANCE MONITOR
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM
TRANSMISSION CONTROLLER
SENSORS
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
ETHER START CIRCUIT
ELECTRIC TRANSMISSION CONTROL
COMBINATION SWITCH
KICK-DOWN/HOLD SWITCH
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS
ELECTRIC PARKING BRAKE CONTROL

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING
SKETCHES FOR SPECIAL TOOLS
MEASURING ENGINE SPEED
MEASURING INTAKE MANIFOLD PRESSURE
MEASURING INTAKE AIR RESTRICTION
MEASURING ENGINE LUBRICATING OIL PRESSURE
MEASURING FUEL FILTER INLET RESTRICTION
MEASURING BLOW-BY PRESSURE
MEASURING EXHAUST BACK PRESSURE
MEASURING COOLANT TEMPERATURE
MEASURING AND ADJUSTING VALVE CLEARANCE
ALTERNATOR DRIVE BELT
AIR CONDITIONER BELT
MEASURING EXHAUST TEMPERATURE
EXHAUST GAS COLOR
MEASURING ENGINE STALL SPEEDS
MEASURING TORQUE CONVERTER STALL
MEASURING HYDRAULIC STALL
MEASURING FULL STALL
ADJUSTING ENGINE SPEED SENSOR
MEASURING SHIFT LEVERS
MEASURING ACCELERATOR PEDAL
MEASURING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE
FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
TESTING AND ADJUSTING STEERING WHEEL
STEERING OIL PRESSURE
STEERING STOP VALVE
MEASURING BRAKE PEDAL
MEASURING BRAKE PERFORMANCE
TESTING BRAKE OIL PRESSURE
MEASURING BRAKE DISC WEAR
PARKING BRAKE PERFORMANCE
PARKING BRAKE OIL PRESSURE
PARKING BRAKE DISC WEAR
MANUAL RELEASE METHOD FOR PARKING BRAKE
PPC OIL PRESSURE
ADJUSTING PPC VALVE LINKAGE
ACCUMULATOR CHARGE PRESSURE
WORK EQUIPMENT HYDRAULIC PRESSURE
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
ADJUSTING WORK EQUIPMENT LEVER LINKAGE
BLEEDING AIR
BUCKET POSITIONER
BOOM POSITIONER
TRANSMISSION CONTROLLER
ADJUSTING MAIN MONITOR (SPEED MODULE)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
HANDLING CONNECTORS
PRECAUTIONS WHEN TROUBLESHOOTING
METHOD OF READING ROUBLESHOOTING TABLES
PREVENTING RECURRENCE OF TROUBLE
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANIS
TRANSMISSION CONTROL SYSTEM
MAIN MONITOR SYSTEM
MAINTENANCE MONITOR SYSTEM
ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) CONTROL SYSTEM
JOYSTICK STEERING CONTROL SYSTEM
METHOD OF DISPLAYING ACTION AND FIALURE CODE
CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION
TRANSMISSION CONTROLLER LED DISPLAY
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT CHARTS
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEM ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
T-1 FAILURE CODE [10](SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP LAMP RELAY) IS DISPLAYED
T-2 FAILURE CODE [12](SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED
T-3 FAILURE CODE [13](SHORT CIRCUIT, DISCONNECTIONS, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED
T-4 FAILURE CODE [14] (SHORT CIRUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED
T-6 FAILURE CODE [16](SHORT CIRUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOUCE IN 4TH SOLENOID) IS DISPLAYED
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH
T-11 FAILURE CODE [22](DISCONNECTIONS IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE SYSTEM) IS DISPLAYED
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMC FILL SWITCH SYSTEM) IS DISPLAYED
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM) IS DISPLAYED
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM) IS DISPLAYED
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM) IS DISPLAYED
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM) IS DISPLAYED
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM) IS DISPLAYED
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD OR 4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED
T-23 HOLD SWITCH SYSTEM
T-24 KICK-DOWN SWITCH SYSTEM
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM
T-27 BUZZER SIGNAL SYSTEM
T-28 NETWORK SYSTEM
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
TROUBLE DATA DISPLAY
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND HAZARD SYSTEM
M-1 MAIN MONITOR DOES NOT WORK
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
M-4 ABNORMALITY IN SHIFT INDICATOR
A) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F
B) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R
C) DOES NOT DISPLAY N WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F
D) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R
E) DOES NOT DISPLAY 1ST-4TH
M-5 HIGH BEAM DOES NOT LIGHT UP
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
A) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP
B) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP
M-7 ABNORMALITY IN PARKING DISPLAY
A) PARKING LAMP DISPLAY DOES NOT LIGHT UP
B) PARKING LAMP DISPLAY STAYS LIGHTED UP
M-9 NIGHT LIGHTING DOES NOT LIGHT UP
M-10 ABNORMALITY IN FRONT WORKING LAMP
A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP
B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
C) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP
M-11 ABNORMALITY IN REAR WORKING LAMP
A) NEIGHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP
B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP
C) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
A) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE
B) WHEN MONITOR SWITCH IS OFF MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED
C) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED
D) CUT-OFF FUNCTION IS ALWAYS ACTUATE REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)
E) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
A) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N
B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED
A) ACTUATED CONTINUOUSLY
B) NOT ACTUATED
M-15 ABNORMALITY IN BUZZER
A) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS)(DURING SELF-CHECK)
B) BUZZER ALWAYS SOUNDS
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY
M-17 ABNORMALITY IN FAILURE DISPLAY MODE
A) DOES NOT ENTER FAILURE DISPLAY MODE
B) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE
M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY
A) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP
B) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY
M-21 ABNORMALITY IN AUTO-GREASING SYSTEM
A) FORCED GREASING CANNOT BE CARRIED OUT
B) MONITOR DISPLAY FLASHES RAPIDLY (2 TIME/SEC)
C) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)
D) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY
E) MONITOR DISPLAY GOES OUT
M-22 ABNORMALITY IN ECSS SYSTEM
A) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED
B) MONITOR DISPLAY LIGHT UP BUT ECSS FUNCIOTN DOES NOT WORK
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR ( ABNORMALITY IN NETWORK
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SEC, MAINTENANCE MONITOR DOES NOT
A) NO LAMPS ON MAINTENANCE MONITOR DOES NOT WORK
B) SOME LAMPS DO NOT LIGHT UP
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNE ON (WITHIN 3 SECS), NO LAMPS ON MAINTENANCE MONITOR GO OUT
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH
A) ENGINE OIL LEVEL DISPLAY FLASHES
B) ENGINE WATER LEVEL DISPLAY FLASHES
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH
A) ENGINE OIL PRESSURE DISPLAY FLASHES
B) BATTERY CHARGE LEVEL DISPLAY FLASHES
C) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE OIL PRESSURE IS CORRECT)
D) AIR CLEANER DISPLAY FLASHES
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH
A) CHECK LAMP
B) CAUTION LAMP
K-9 THERE IS NO ABNORMALITY IN MAINTENANCEMONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHT UP
A) CHECK LAMP
B) CAUTION LAMP
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF NIGHT LIGHTING STAYS LIGHTED UP
K-12 SERVICE METER DOES NOT WORK
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED
K-14 ABNORMALITY IN GAUGE ITEMS
A) ABNORMALITY IN FUEL GAUGE
B) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING/STOP SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
E-1 ENGINE DOES NOT START
A) ENGINE DOES NOT START
B) STARTING MOTOR TURNS
E-2 ENGINE DOES NOT STOP
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING
E-4 NOT USED
E-5 PARKING BRAKE DOES NOT HAVE EFFECT
A) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (ACTUATED)
B) PARKING BRAKE HAS NOT EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKES)
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)
E-9 KICK-DOWN SWITCH DOES NOT WORK
A) KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING NORMAL GEAR SHIFT OPERATIONS)
B) KICK-DOWN IS NOT CANCELED
E-10 BOOM KICK-OUT CANNOT BE USED
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION
E-12 ABNORALITY IN LIGHTING UP OF FRONT WORKING LAMP
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
E-16 ABNORMALITY IN BUZZER
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
POWER TRAIN
H-1 MACHINE DOES NOT START
H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES, DOES NOT SHIFT GEAR
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE ARE SHIFTING GEAR
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OF SHIFTING GEAR
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
STEERING SYSTEM
H-6 STEERING WHEEL DOES NOT TURN
H-7 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]
H-8 TURNING, RESPONSE OF STEERING IS POOR
H-9 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]
H-10 STEERING IS HEAVY
H-11 JOYSTICK STEERING IS HEAVY
H-12 STEERING WHEEL SHAKES OR JERKS
H-13 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK)
H-14 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING
BRAKE SYSTEM
H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
H-16 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG
H-17 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR
H-18 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)
WORK EQUIPMENT
H-19 NEITHER BOOM NOR BUCKET MOVE
H-20 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER
H-21 BOOM DOES NOT MOVE
H-22 NOT USED
H-23 BOOM IS SLOW OR BOOM LACKS POWER
H-24 NOT USED
H-25 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT
H-27 NOT USED
H-28 EXCESSIVE HYDRAULIC DRIFT OF BOOM
H-29 BUCKET DOES NOT MOVE
H-30 BUCKET IS SLOW OR LACKS POWER
H-31 EXCESSIVE HYDRUALIC DRIFT OF BUCKET
H-32 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE)
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
D-1 ECSS DOES NOT WORK
A) ERROR CODE [D0] IS DISPLAYED
B) ERROR CODE [D1] IS DISPLAYED
C) ERROR CODE [D2] IS DISPLAYED
D) ERROR CODE [D3] IS DISPLAYED
E) NO ABNORMALITY DISPLAY IS GIVEN
D-2 ECSS CANNOT BE CANCELED
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION DISPLAY OUTPUT) IS DISPLAYED
J-2 FAILURE CODE [57](SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
J-4 FAILURE CODE [59](SHORT CIRUIT IN STEERING RIGHT SOLENOID (HOT END) IS DISPLAYED
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)) IS DISPLAYED
J-6 FAILURE CODE [61](SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IS JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMTER SYSTEM) IS DISPLAYED (NOT USED)
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID
J-12 DISCONNECTION IN STEERING LEFT SOLENOID
TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM (C MODE)
ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
C-1 WHEN ENGINE IS RUNNING, ENGINE OIL LEVEL DISPLAY SHOWS 'ABNORMAL"
C-2 WHEN ENGINE IS RUNNING, BATTERY ELECTROLYTE LEVEL DISPLAY SHOWS " ABNORMAL"
C-3 ABNORMALITY IN ENGINE COOLANT LEVEL DISPLAY
A) DISPLAY SHOWS "ABNORMAL"
B) DISPLAY SHOWS "DISCONNECTION"
C) DISPLAY SHOWS "SHORT CIRCUIT"
C-4 ABNORMALITY IN BRAKE OIL PRESSURE DISPLAY
A) WHEN ENGINE IS RUNNING, DISPLAY SHOWS "ABNORMAL"
B) DISPLAY SHOWS "DISCONNECTION"
C) DISPLAY SHOWS "SHORT CIRCUIT"
C-5 ABNORMALITY IN ENGINE OIL PRESSURE DISPLAY
A) WHEN ENGINE IS RUNNING, DISPLAY SHOWS "ABNORMAL"
B) WHEN ENGINE IS STOPPED OR RUNNING, DISPLAY SHOWS "DISCONNECTION"
C) ONLY WHEN ENGINE IS STOPPED, DISPLAY SHOWS "DISCONNECTION"
D) DISPLAY SHOWS "SHORT CIRCUIT"
C-6 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), BATTERY CHARGE DISPLAY SHOWS "ABNORMAL"
C-7 WHEN STARTING SWITCH IS AT ON (ENGINE STARTED), AIR CLEANER DISPLAY SHOWS "ABNORMAL"
C-8 CAUTION ITEM DISPLAY SHOWS "ABNORMAL", BUT ALARM BUZZER DOES NOT SOUND
C-9 MONITOR DISPLAY DOES NOT SHOW "ABNORMAL", BUT ALARM BUZZER SOUNDS
C-10 CAUTION ITEM DISPLAY SHOWS "ABNORMAL," BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT FLASH
A) CHECK LAMP
B) CAUTION LAMP
C-11 MONITOR DISPLAY DOES NOT SHOW ANY ABNORMALITY, BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHT UP
A) CHECK LAMP
B) CAUTION LAMP
C-12 SERVICE METER DOES NOT WORK
C-13 SERVICE METER IS RUNNING WHEN ENGINE IS STOPPED
C-14 ABNORMALITY IN FUEL GAUGE
A) DISPLAY SHOWS "DISCONNECTION" OF LOW FUEL LEVEL
B) DISPLAY ALWAYS SHOWS FULL AND DOES NOT GO DOWN
C-15 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
A) DISPLAY SHOWS "SHORT CIRCUIT"
B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE
C-16 ABNORMILITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE
A) DISPLAY SHOWS "SHORT CIRCUIT"
B) DISPLAY ALWAYS SHOWS LOWEST LEVEL AND DOES NOT GO UP
C-17 WHEN STARTING SWITCH IS TURNED TO ON, MONITOR IS NOT ACTUATED (KOMATSU IS NOT DISPLAYED)
A) MAIN MONITOR CHECK LAMPS DO NOT LIGHT UP
B) MAIN MONITOR CHECK LAMPS LIGHT UP
C-18 DOES NOT SWITCH TO WORKING MEMORY (ENGINE RUNNING) MODE, OR SWITCHES TO CHECK BEFORE STARTING MODE WHEN ENGINE IS RUNNING
C-19 ABNORMALITY IN MDC MONITOR DISPLAY
A) DISPLAY COLOR IS NORMAL
B) DISPLAY FLICKERS
C-20 EVEN WHEN SWITCH IS OPERATED, NOTHING FUNCTIONS
C-21 DOES NOT SWITCH TO TV/VIDEO MODE
A) STAYS AT PARKING BRAKE APPLIED DISPLAY
B) DISPLAY DOES NOT LIGHT UP
C-22 ABNORMALITY IN MEMORY DATA
A) LOAD METER DATA IS NOT SAVED TO MEMORY
B) MAINTENANCE TIME IS NOT SAVED TO MEMORY
C-23 ENGINE SPEED STAY AT 0 RPM
C-24 PRESSURE SENSOR DISPLAY SHOWS "DISCONNECTION"
A) SENSOR POWER SOURCE DISPLAY SHOWS "ABNORMAL"
B) ONLY PRESSURE SENSOR DISPLAY SHOWS "DISCONNECTION"
C-25 LOAD METER CANNOT WEIGH LOAD
A) CANNOT CARRY OUT CALIBRATION
B) CAN CARRY OUT CALIBRATION
C-26 ABNORMALITY IS LEVER SWITCH
A) SUB-TOTAL SWITCH DOES NOT WORK
B) CANCEL SWITCH DOES NOT WORK
C-27 PRINTER DOES NOT PRINT OUT
C-28 ABNORMALITY IN ANTENNA SYSTEM
C-29 ABNORMALITY IN SPEAKER SYSTEM
A) ABNORMALITY IN RIGHT SPEAKER
B) ABNORMALITY IN LEFT SPEAKER
TROUBLESHOOTING AIR CONDITIONING
AIR CONDITIONER/HEATER (DENSO)
VISUAL AND AUDIBLE INSPECTION
TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)
TROUBLESHOOTING THE ELECTRICAL CIRCUIT
COOLER CIRCUIT TROUBLESHOOTING
WIRING DIAGRAM

30 DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATIONS
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR ASSEMBLY
REMOVAL
INSTALLATION
ALTERNATOR ASSEMBLY
REMOVAL
INSTALLATION
ENGINE OIL COOLER
REMOVAL
INSTALLATION
FUEL INJECTION PUMP ASSEMBLY
REMOVAL
INSTALLATION
WATER PUMP ASSEMBLY
REMOVAL
INSTALLATION
INJECTOR ASSEMBLY
REMOVAL
INSTALLATION
TURBOCHARGER ASSEMBLY
REMOVAL
INSTALLATION
AFTER COOLER ASSEMBLY
REMOVAL
INSTALLATION
CYLINDER HEAD ASSEMBLY
REMOVAL
INSTALLATION
RADIATOR ASSEMBLY
REMOVAL
INSTALLATION
DAMPER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER AND TRANSMISSION
REMOVAL
INSTALLATION
DISCONNECTION
CONNECTION
TORQUE CONVERTER ASSEMBLY
DISASSEMBLY
ASSEMBLY
TRANSMISSION ASSEMBLY
DISASSEMBLY
ASSEMBLY
TRANSFER ASSEMBLY
DISASSEMBLY
ASSEMBLY
PARKING BRAKE ASSEMBLY
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE ASSEMBLY (ECMV ASSEMBLY)
REMOVAL
INSTALLATION
CENTER SUPPORT ASSEMBLY
REMOVAL
DISASSEMBLY
ASSEMBLY
DISASSEMBLY OF DRIVE SHAFT
ASSEMBLY OF DRIVE SHAFT
REMOVAL OF FRONT AXLE ASSEMBLY
INSTALLATION OF FRONT AXLE ASSEMBLY
REMOVAL OF FRONT DIFFERENTIAL ASSEMBLY
INSTALLATION OF FRONT DIFFERENTIAL ASSEMBLY
REMOVAL OF REAR AXLE ASSEMBLY
INSTALLATION OF REAR AXLE ASSEMBLY
REMOVAL OF REAR DIFFERENTIAL ASSEMBLY
INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
FINE DISASSEMBLY OF PINION ASSEMBLY
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY
FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY
FINE ASSEMBLY OF PINION ASSEMBLY
ASSEMBLY OF DIFFERENTIAL ASSEMBLY
DISASSEMBLY OF FINAL DRIVE ASSEMBLY
ASSEMBLY OF FINAL DRIVE ASSEMBLY
REMOVAL OF ORBIT ROLL ASSEMBLY
INSTALLATION OF ORBIT-ROLL ASSEMBLY
DISASSEMBLY OF ORBIT-ROLL ASSEMBLY
ASSEMBLY OF ORBIT-ROLL ASSEMBLY
REMOVAL OF STEERING CYLINDER ASSEMBLY
INSTALLATION OF STEERING CYLINDER ASSEMBLY
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY
ASSEMBLY OF STEERING CYLINDER ASSEMBLY
REMOVAL OF STEERING VALVE ASSEMBLY
INSTALLATION OF STEERING VALVE ASSEMBLY
REMOVAL OF BRAKE VALVE ASSEMBLY
INSTALLATION OF BRAKE VALVE ASSEMBLY
REMOVAL OF SLACK ADJUSTER ASSEMBLY
INSTALLATION OF SLACK ADJUSTER ASSEMBLY
DISASSEMBLY OF SLACK ADJUSTER
ASSEMBLY OF SLACK ADJUSTER
REMOVAL OF BRAKE ASSEMBLY (FRONT, REAR)
INSTALLATION OF BRAKE ASSEMBLY (FRONT, REAR)
DISASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR)
ASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR)
REMOVAL OF HYDRAULIC PUMP (SWITCH & PPC, LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY
INSTALLATION OF HYDRAULIC PUMP (SWITCH & PPC LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY
REMOVAL OF HYDRAULIC TANK ASSEMBLY
INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL OF HYDRAULIC FILTER ASSEMBLY
INSTALLATION OF HYDRAULIC FILTER ASSEMBLY
REMOVAL OF PPC VALVE ASSEMBLY
INSTALLATION OF PPC VALVE ASSEMBLY
DISASSEMBLY OF PPC VALVE ASSEMBLY
ASSEMBLY OF PPC VALVE ASSEMBLY
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY
ASSEMBLY OF MAIN CONTROL VALVE
REMOVAL OF BUCKET CYLINDER ASSEMBLY
INSTALLATION OF BUCKET CYLINDER ASSEMBLY
REMOVAL OF BOOM CYLINDER ASSEMBLY
INSTALLATION OF BOOM CYLINDER ASSEMBLY
DISASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY
ASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY
REMOVAL OF CENTER HINGE PIN
INSTALLATION OF CENTER HINGE PIN
REMOVAL OF WORK EQUIPMENT
INSTALLATION OF WORK EQUIPMENT ASSEMBLY
REMOVAL OF BULKHEAD ASSEMBLY
INSTALLATION OF BULKHEAD ASSEMBLY
REMOVAL OF ENGINE HOOD ASSEMBLY
INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL OF FLOOR FRAME ASSEMBLY
INSTALLATION OF FLOOR FRAME ASSEMBLY
REMOVAL OF COUNTERWEIGHT
INSTALLATION OF COUNTERWEIGHT
REMOVAL OF FUEL TANK ASSEMBLY
INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL OF CAB ASSEMBLY
INSTALLATION OF CAB ASSEMBLY
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY
INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY
INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY
REMOVAL OF RECEIVER TANK
INSTALLATION OF RECEIVER TANK
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY

40 MAINTENANCE STANDARD
ENGINE MOUNT
TRANSMISSION MOUNT
TORQUE CONVERTER CHARGING PUMP
DAMPER
TORQUE CONVERTER AND PTO
TRANSMISSION
TRANSFER
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
LUBRICATION RELIEF VALVE
DRIVE SHAFT
CENTER SUPPORT
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
STEERING COLUMN
STEERING PUMP
STEERING VALVE
STEERING CYLINDER MOUNT
BRAKE VALVE
SLACK ADJUSTER
BRAKE
PARKING BRAKE
HYDRAULIC PUMP
SWITCH AND PPC PUMP
PPC VALVE
CUT-OFF VALVE
MAIN CONTROL VALVE
HYDRAULIC CYLINDERS
BUCKET LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
ROPS CAB

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