Komatsu Wheel Loaders WA500H Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA500-3H, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loaders WA500-3H workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,623 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
VEAM430100 - Wheel Loader WA500-6H Operation & Maintenance Manual.pdf
VEAM500100 - Wheel Loader WA500-3H Operation & Maintenance Manual.pdf
VEBM500100 - Wheel Loader WA500-3H Shop Manual.pdf
MAIN SECTIONS
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
