Komatsu WA800-3E0, WA900-3E0 Wheel Loader Service Manual - PDF Download

SEN05654-00

WHEEL LOADER

WA900 -3E0 SERIAL NUMBERS

60079

and up

SEN0565402-00

0 -1

WA900-3E0

WHEEL LOADER WA900-3E0 Shop Manual

Machine model

Serial number

WA900-3E0

60079 and up

00 Index and foreword

WA900-3E0

0-1

0 -1

00-1

Table of Contents

Table of Contents

0 -2

00 Index and foreword Table of Contents....................................................................................................................

Table of Contents.................................................................................................................

Foreword.................................................................................................................................

Before reading this manual ..................................................................................................

00000000-

2 2 6 6

01 Specification Specification............................................................................................................................

Specification dimension drawing..........................................................................................

Specifications.......................................................................................................................

Weight table .........................................................................................................................

Table of fuel, coolant and lubricants ....................................................................................

0101010101-

3 3 4 7 9

10 Structure and function Cooling system and related devices .......................................................................................

Cooling system ....................................................................................................................

Hydraulic system.....................................................................................................................

Power ladder system ...........................................................................................................

Electrical system .....................................................................................................................

Power ladder controller ........................................................................................................

Rear view monitor system....................................................................................................

Engine service monitor system ............................................................................................

Parking brake circuit ............................................................................................................

Sensor..................................................................................................................................

10101010101010101010-

3 3 5 5 10 10 19 22 24 26

20 Standard value table Standard value table ............................................................................................................... 20Standard value table for chassis.......................................................................................... 20Standard value table for electrical system ........................................................................... 20-

3 3 4

30 Testing and adjusting Testing and adjusting ..............................................................................................................

Inspection and adjustment of potentiometer ........................................................................

Ladder position calibration procedure..................................................................................

Procedure for testing diodes ................................................................................................

30303030-

3 3 4 6

404040404040404040404040-

4 4 5 7 9 9 11 12 13 14 15 16

40 Troubleshooting General information on troubleshooting..................................................................................

Classification and procedures of troubleshooting ................................................................

Failure codes table...............................................................................................................

Fuse locations......................................................................................................................

Troubleshooting by failure code..............................................................................................

Failure code [D1EMKA] (Disconnection of parking brake interlock relay) ...........................

Failure code [D1EMKB] (Ground fault of parking brake interlock relay) ..............................

Failure code [D1EMKY] (Hot short of parking brake interlock relay) ...................................

Failure code [D1EPKA] (Disconnection of ladder drive pump relay) ...................................

Failure code [D1EPKB] (Ground fault of ladder drive pump relay) ......................................

Failure code [D1EPKY] (Short circuit of ladder drive pump relay) .......................................

Failure code [D1EQKY] (Ladder operation alarm relay output hot short circuit)..................

Failure code [D1EQKZ] (Ladder operation alarm relay output abnormality: Open circuit, ground fault) ........................................................................................

00-2

40- 17

WA900-3E0

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Table of Contents

Failure code [D1ERKB] (Ladder raise solenoid output ground fault)................................... 40Failure code [D1ERKZ] (Ladder raise solenoid output abnormality: Open circuit, hot short circuit)................................................................................... 40Failure code [D1ESKB] (Ladder lower solenoid output ground fault) .................................. 40Failure code [D1ESKZ] (Ladder lower solenoid output abnormality: Open circuit, hot short circuit)................................................................................... 40Failure code [DBL0KR] (Power ladder controller CAN-NET signal line open circuit) .......... 40Failure code [DBL0KT] (Non-volatile memory write error) ................................................... 40Failure code [DBL1KK] (Power Low Error: Battery direct) ................................................... 40Failure code [DBL2KK] (Solenoid Power Low Error) ........................................................... 40Failure code [DDB6KZ] (Parking brake system abnormality) .............................................. 40Failure code [DDDGKY] (Ladder operation switch hot short circuit).................................... 40Failure code [DDDKKY] (Ladder raise operation switch hot short circuit) ........................... 40Failure code [DDDLKY] (Ladder lower operation switch hot short circuit) ........................... 40Failure code [DK5VKX] (Ladder angle sensor abnormality: Out of range) .......................... 40Failure code [DK5VMA] (Power ladder system abnormality)............................................... 40Failure code [DUM9KY] (Ladder indicator output hot short circuit) ..................................... 40Failure code [DUM9KZ] (Ladder indicator output abnormality: Open circuit, hot short circuit)40Failure code [DV00KY] (Ladder interlock caution output hot short circuit) .......................... 40Failure code [DV00KZ] (Ladder interlock caution output abnormality: Open circuit, ground fault) ........................................................................................ 40Failure code [DWNLKA] (Ladder cushion valve output open circuit)................................... 40Failure code [DWNLKB] (Ladder cushion valve output ground fault) .................................. 40Failure code [DWNLKY] (Ladder cushion valve output hot short circuit) ............................. 40Troubleshooting of electrical system (E-mode)....................................................................... 40E-1 Power ladder does not operate ..................................................................................... 40E-2 Brake oil temperature warning keeps lighting ............................................................... 40E-3 Parking brake does not operate (as emergency brake) ................................................ 40E-4 Parking brake is applied while machine is traveling. ..................................................... 40E-5 Parking brake is released as starting switch is turned to ON position. ......................... 40Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40H-1 Power ladder does not move or its speed is low........................................................... 40H-2 Fan of ADD cooler does not rotate ............................................................................... 40Troubleshooting of maintenance monitor system (K mode) ................................................... 40Maintenance monitor system............................................................................................... 40K-1 Hydraulic oil level gauge flashes................................................................................... 40Troubleshooting for machine monitor (M-mode)..................................................................... 40M-1 Rear view monitor does not operate............................................................................. 40M-2 While clearance lamp is turned on, illuminance of rear view monitor remains dark ..... 40M-3 Rear view monitor does not work in reverse-interlock mode ........................................ 40M-4 Illuminance of rear view monitor cannot be adjusted ................................................... 40M-5 Optional controller error and real-time monitor sreen are not displayed on engine service monitor ........................................................................................ 40M-6 Engine compartment lamp does not light up ................................................................ 40M-7 Step lamp does not light up .......................................................................................... 4090 Diagrams and drawings Hydraulic circuit diagram ........................................................................................................

Symbols used in hydraulic circuit diagram...........................................................................

Power train hydraulic circuit diagram...................................................................................

Brake, power ladder and additional cooler hydraulic circuit diagram...................................

Work equipment hydraulic circuit diagram...........................................................................

Electrical circuit diagram .........................................................................................................

Symbols used in electric circuit diagram..............................................................................

WA900-3E0

18 19 20 21 22 26 27 29 31 33 35 38 41 43 46 47 48 49 50 51 52 53 53 56 58 62 65 67 67 68 69 69 71 74 74 77 78 80 82 84 87

90- 3 90- 3 90- 7 90- 9 90- 11 90- 13 90- 13 00-3

Table of Contents

Electrical circuit diagram ...................................................................................................... 90- 17 Connector arrangement diagram ......................................................................................... 90- 21

00-4

WA900-3E0

Table of Contents

WA900-3E0

00-5

Foreword Before reading this manual

Foreword

0 -6

Before reading this manual

0 -6

q q

This shop manual describes only the different part from the standard machine (WA900-3E0: S/N 60079 and up).

For the component that is not described in this manual, refer to the shop manual for the standard machine (WA900-3E0: S/N 60079 and up).

00-6

WA900-3E0

SEN0565404-00

01-

WA900-3E0

WHEEL LOADER WA900-3E0 Shop Manual

Machine model

Serial number

WA900-3E0

60079 and up

01 Specification

WA900-3E0

01-

01-

01-1

Contents

Contents 01 Specification Specification............................................................................................................................

Specification dimension drawing..........................................................................................

Specifications.......................................................................................................................

Weight table .........................................................................................................................

Table of fuel, coolant and lubricants ....................................................................................

01-2

01-2 0101010101-

3 3 4 7 9

WA900-3E0

Specification Specification dimension drawing

Specification

01-3

Specification dimension drawing

01-3

WA900-3E0

01-3

WA900-3E0

01-3

Specification Specifications

Performance

Weight

Specifications

01-4

Machine model

WA900-3E0

Serial number

60079 and up

Operating weight

kg

111,200

Load on front axle

kg

62,020

Load on rear axle

kg

49,180

Bucket capacity (heaped)

m3

13.0

Operating load

kg

23,400

Travel speed Forward 1st

km/h

7.0

Travel speed Forward 2nd

km/h

12.3

Travel speed Forward 3rd

km/h

28.0

Travel speed Reverse 1st

km/h

7.1

Travel speed Reverse 2nd

km/h

12.4

Travel speed Reverse 3rd

km/h

28.3

Maximum rim pull

kN {kg}

588.4 {60,000}

Gradeability

degree

25

Center of outside tire

mm

9,200

Outside of chassis (bucket with teeth)

mm

11,000

Overall length (bucket with teeth)

mm

14,058

Overall width (chassis)

mm

4,585

Bucket width (outside of cutting edge)

mm

4,810

Bucket width (with tire guards)

mm

5,045

Overall height (to top of ROPS cab)

mm

5,275

Overall height (with bucket fully raised)

mm

9,680

Wheelbase

mm

5,450

Tread

mm

3,350

Min. ground clearance

mm

295

Maximum bucket hinge pin height

mm

6,960

mm

4,640/5,020

mm

2,450/2,215

degree

47

degree

60

mm

470/645

Dimension

Min. turning radius

Dumping clearance (tooth tip / cutting edge end) Dumping reach (tooth tip / cutting edge end) Bucket tilt-forward angle Bucket tilt-back angle (traveling posture) Digging depth, 10 deg. (tooth tip / cutting edge end)

01-4

WA900-3E0

Specification Specifications

Machine model

WA900-3E0

Serial number

60079 and up

Komatsu SAA12V140E-3 4-cycle, water-cooled, V type 12-cylinder, direct injection, with twin turbochargers and aftercooler

Model Type Number of cylinders – Bore x Stroke

mm

12 – 140 x 165

Total displacement

l{cc}

30.48 {30, 480}

kW/rpm {PS/rpm} Nm/rpm {kgm/rpm} g/kWh {g/PSh}

4,089 {417}/1,300

Max. speed with no load

rpm

2,200

Min. speed with no load

rpm

650

Engine

Flywheel horsepower Maximum torque Rated fuel consumption rate

Starting motor

24 V, 90 A x 2

Power train system

Battery

12 V, 200 Ah x 2

Torque converter

3-element, 1-stage, 1-phase (TCA51-1A) Planetary gear, 3-forward and 3-reverse speeds (KTM3365)

Transmission Reduction gear unit

Spiral bevel gear type

Differential

Straight bevel gear type

Final reduction gear

Planetary gear, single reduction, oil bath type

Drive method Wheel and axle

200.4 {147.72}

24 V, 7.5 kW x 2

Alternator

Front and rear wheel drive

Front axle

Full floating type, fixed to frame

Rear axle

Full floating type, supported by center pin

Tire

45 / 65 – 45 – 58 PR (L–5)

Wheel rim Inflation pressure

Brake

638 {820}/2,050

36.00 x 45 WTB kPa

{kg/cm2}

667 {6.8}

Foot brake

Wet, multiple disc type brakes acting on front and rear wheels independently

Hand brake

Dry disc type brake acting on drive shaft (front axle), hydraulically released and spring applied

Steering system Type Structure

WA900-3E0

Frame articulation steering Full hydraulic power steering

01-5

Work equipment

Control valve set pressure Cylinder

Hydraulic system

Delivery of hydraulic pump

Specification Specifications

01-6

Machine model

WA900-3E0

Serial number

60079 and up

Torque converter and transmis sion pump

l/min

Steering pump

l/min

Switching pump

l/min

PPC pump

l/min

Brake pump

l/min

Work equipment pump

l/min

Front brake cooling pump

l/min

Rear brake cooling pump

l/min

Power ladder pump

l/min

Transmission valve

MPa {kg/cm2}

432 (Gear pump SAR (4) 112 + SAR (3) 100) 315 (Fixed displacement piston pump HPF76 + 71) 415 (Variable displacement piston pump HPV90 + 90) 70 (Gear pump ASR (1) 32) 30 (Gear pump SAR (1) 14) 415 (Variable displacement piston pump HPV90 + 90) 47 (Gear pump SBL (1) 24) 47 (Gear pump SBR (1) 24) 1.8 (0.8 to 841 U) 2.5 {25} (Spool type, electrically controlled)

Steering valve

MPa

{kg/cm2}

31.4 {320} (Spool type)

PPC valve

MPa {kg/cm2}

3.7 {38} (2-lever type)

Work equipment valve

MPa {kg/cm2}

34.3 {350} (2-spool type)

Ladder valve

MPa {kg/cm2}

RAISE 15 {153} / LOWER 12 {122} (Spool type, electrically controlled)

mm

Double-acting piston type, 2 - 160 x 503

mm

Double-acting piston type, 2 - 260 x 1,368

mm

Double-acting piston type, 1 - 300 x 906

mm

Double-acting piston type, 1 - 40 x 270

Steering cylinder No. of cylinders – bore x stroke Lift arm cylinder No. of cylinders - bore x stroke Bucket cylinder No. of cylinders - bore x stroke Ladder cylinder No. of cylinders - bore x stroke

Type of link Shape of bucket edge

Single Z-bar link Spade nose edge with tip teeth

WA900-3E0

Specification Weight table

Weight table

01-7 Unit: kg Machine model

WA900-3E0

Serial number

60079 and up

Engine (dry weight)

3,690

Radiator (dry weight)

880

Torque converter (dry weight)

590

Transmission (dry weight)

2,300

Damper

178

Upper drive shaft

58

Center drive shaft

184

Front drive shaft

171

Rear drive shaft

184

Center support

165

Front axle

8,190

Rear axle

7,700

Front differential (excluding parking brake)

1,226

Rear differential

1,256

Planetary carrier assembly (per assembly)

238

Wheel hub (per hub)

600

Axle pivot (rear)

286

Wheel (per wheel)

874

Tire (per tire)

2,720

Steering control valve

66

Steering cylinder (per cylinder)

206

Hydraulic tank (dry weight)

824

Work equipment pump

150

Parking brake assembly

185

Torque converter charging pump and PPC pump

49

Switching pump

157

Steering pump

145

Fender and guard assembly

1,393

PPC valve

4

Work equipment control valve (per valve)

95

Hydraulic oil cooler

400

ADD cooler (TC & HYD)(dry weight)

206

Front brake cooler (dry weight)

45

Rear brake cooler (dry weight)

45

Front brake cooling pump

3

Rear brake cooling pump

3

Fan motor for ADD cooler

5

WA900-3E0

01-7

Specification Weight table

Unit: kg Machine model

WA900-3E0

Serial number

60079 and up

Ladder pump motor

6

Ladder power unit (including motor and bracket) assembly

59

Ladder cylinder

5

Ladder assembly

361

Lift arm cylinder (per cylinder)

998

Bucket cylinder

1,210

Engine hood (top hood / each side hood)

88/28

Front frame

7,891

Rear frame

9,644

Bucket link (including bushing)

566

Bell crank (including bushing)

1,850

Lift arm (including bushing)

8,690

Bucket (with teeth)

12,320

Counterweight

2,200 + 2,600

Fuel tank

806

Battery (per battery)

64

Cab

447

Air conditioner unit

55

Operator's seat

50

Floor board

419

ROPS support assembly

01-8

1,387

WA900-3E0

Specification Table of fuel, coolant and lubricants

Table of fuel, coolant and lubricants

WA900-3E0

01-9

01-9

Specification Table of fuel, coolant and lubricants

Reservoir

Capacity

Engine oil pan

Transmission case

Hydraulic system

Brake oil tank

Specified capacity

l

140

164

1,065

42

Refill capacity

l

130

140

725

31

Axle 360 each for front and rear axles 360 each for front and rear axles

Pins

Fuel tank

Cooling system

Power ladder

–

1,555

337

3

–

–

–

2

Important Fuel used must be JIS diesel fuel.

The engine of this machine employs the electronically controlled high-pressure fuel injection unit in order to secure good fuel economy and cleaner exhaust gas. Since this unit requires high parts accuracy and lubricating ability, its durability can be seriously degraded if low-viscosity fuel with low lubricating ability is used.

Note 1: Power train oil and engine oil are not identical. Use the recommended oil for each.

Note 2: When environmental preservation is an important factor for the give operation including river work, marine and shore work and forest work, use of bio hydraulic oil and bio grease is recommended.When using the oil and grease, please contact your Komatsu distributor for advice.

Note 3: Axle oil AX080 is capable of preventing creaking of the differential due to slippage and creaking of the brakes. When the name AX080 alone is specified, use Komatsu genuine AX080.

Note 4: When using the machine equipped with the auto-greasing unit at temperatures below -20 °C, use Lithium Grease No.0.

Note 5: Hyper white greases (G0-T, G2-T) are high-performance white greases.

Use of G0-T or G2-T is recommended for the following cases.

(1) When enhanced lubricating ability is required for the grease to prevent the pins and bushings from creaking.

(2) When preventing taints on the machine appearance by black grease.

01-10

WA900-3E0

Specification Table of fuel, coolant and lubricants

Features of grease (reference) Part name

High load Wear-resis Heat-resis- Water-resi Biodegradcapacity tant tant stant able

Remarks

Hyper White

w

w

w

w

x

Non-black high load grease

Molybdenum disulfide grease

Q

w

Q

Q

x

Molybdenum grease

Lithium grease

E

Q

Q

Q

x

Biogrease

E

Q

w

Q

w

Synthetic biodegradable grease

w…Excellent Q…Satisfactory E…Average x…Poor

Note 6: Super Coolant (1) Super Coolant has important functions as a corrosion inhibitor for the cooling system in addition to the function of preventing freezing.

It is recommended to use Super Coolant even in an area where antifreeze is not required.

Komatsu does not, in principle, recommend any other coolant than Komatsu Genuine Super Coolant (AF-NAC). Using other brands can induce serious troubles to the cooling system including the engine.

(2) For the mixing proportion of Super Coolant and dilution water, see "Mixing proportion of water and Super Coolant ".

When the machine is shipped, Komatsu genuine Super Coolant AF-NAC is added more than 30% unless otherwise specified. Accordingly, you need not change its concentration as long as the minimum temperature is above -10 °C. If the temperature drops below -10 °C, adjust concentration of Supper Coolant referencing "Mixing proportion of water and Super Coolant".

(3) Be sure to keep the concentration of Super Coolant above 30% to maintain its corrosion inhibition ability.

Mixing proportion of water and Super Coolant

Mixing quantity (l)

Min. temperature ( °C) Above -10

-15

-20

-25

-30

Quantity of Super Coolant

101.1

121.3

138.2

155.0

168.5

Quantity of water

235.9

215.7

198.8

181.9

168.5

WA900-3E0

01-11

Specification Table of fuel, coolant and lubricants

01-12

WA900-3E0

SEN0565406-00

10-1

WA900-3E0

WHEEL LOADER WA900-3E0 Shop Manual

Machine model

Serial number

WA900-3E0

60079 and up

10 Structure and function

WA900-3E0

10-1

10-1

10-1

Contents

Contents 10 Structure and function Cooling system and related devices .......................................................................................

Cooling system ....................................................................................................................

Hydraulic system.....................................................................................................................

Power ladder system ...........................................................................................................

Electrical system .....................................................................................................................

Power ladder controller ........................................................................................................

Rear view monitor system....................................................................................................

Engine service monitor system ............................................................................................

Parking brake circuit ............................................................................................................

Sensor..................................................................................................................................

10-2

10-2 10101010101010101010-

3 3 5 5 10 10 19 22 24 26

WA900-3E0

Cooling system and related devices Cooling system

Cooling system and related devices Cooling system

1.

2.

3.

4.

5.

6.

Hydraulic oil cooler Torque converter oil cooler Front brake oil cooler Rear brake oil cooler Hydraulic oil cooler inlet tube Hydraulic oil cooler outlet tube

WA900-3E0

10-3 10-3

7. Torque converter oil cooler inlet tube 8. Torque converter oil cooler outlet tube 9. Front brake oil cooler inlet tube 10. Front brake oil cooler outlet tube 11. Rear brake oil cooler inlet tube 12. Rear brake oil cooler outlet tube

10-3

Cooling system and related devices Cooling system

Specification Specification

10-4 Torque converter oil cooler

Oil cooler

Front brake oil cooler

Rear brake oil cooler

Model

Core type J6

SF1-4

SF1-4

Fin pitch (mm)

3.0P

3.0P

3.0P

20.17

9.76

9.76

58.72

17.78

17.78

---

---

---

---

---

---

Total heat dissipation area (m2) Cross sectional area of water flow (m2) Valve cracking pressure (kPa {kg/cm2}) Valve closing pressure (kPa {kg/cm2})

10-4

WA900-3E0

Hydraulic system Power ladder system

Hydraulic system

10-5

Hydraulic circuit of ladder system

10-5

Power ladder system

WA900-3E0

10-5

10-5

Hydraulic system Power ladder system

Operation q

10-6

10-6 Pressing the ladder RAISE switch drives ladder pump motor (2) and energizes ladder operation solenoid valve (1) allowing oil to flow to the bottom end of ladder cylinder (7).

When the ladder rises and comes near the storage position, ladder cushion solenoid valve (3) is energized to the throttle the return circuit to the tank. As a result, ladder cylinder (7) slows down.

Pressing the ladder LOWER switch drives ladder pump motor (2) and energizes ladder operation solenoid valve (1) allowing oil to flow to the head end of ladder cylinder (7).

When the ladder lowers and comes near the boarding position, ladder cushion solenoid valve (3) is energized to throttle the return circuit to the tank. As a result, ladder cylinder (7) slows down.

Opening emergency operation valves (5) and(6) connects both bottom and head ends of ladder cylinder (7) to the tank. As a result, ladder cylinder (7) becomes free to move and it can be moved by external force.

The ladder does not move up when a load of 15 kg or greater is applied to the lowest step of the ladder so that it does not start moving up while a worker is on the ladder.

WA900-3E0

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL