Komatsu WA100M-8E0 Wheel Loader Shop Manual VENBM07004 PDF

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Komatsu WA100M-8E0 Wheel Loader Shop Manual VENBM07004 – PDF DOWNLOAD

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Komatsu WA100M-8E0 Wheel Loader Shop Manual VENBM07004 – PDF DOWNLOAD

Language : English
Pages : 1100
Downloadable : Yes
File Type : PDF 

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TABLE OF CONTENTS:

Komatsu WA100M-8E0 Wheel Loader Shop Manual VENBM07004 – PDF DOWNLOAD 

VENBM07004 WA100M-8E0 1
INDEX AND FOREWORD 3
ABBREVIATION LIST 4
List of abbreviations used in the text 4
List of abbreviations used in the circuit diagrams 9
FOREWORD, SAFETY, BASIC INFORMATION 10
HOW TO READ THE SHOP MANUAL 10
Composition of the shop manual 10
Symbols 12
Signal word 12
Unit 12
SAFETY NOTICE FOR OPERATION 13
Safety matters 13
General precautions 14
Precautions for preparatory work 15
Precautions during work 15
Precautions for slinging work and making signals 17
Precautions for using mobile crane 20
Precautions for using overhead traveling crane 20
Selecting wire ropes 21
PRECAUTIONS TO PREVENT FIRE 23
Fire caused by fuel, oil, coolant or window washer fluid 23
Fire caused by accumulation or attachment of flammable material 23
Fire coming from electric wiring 23
Fire caused by piping 24
Fire around the machine due to highly heated exhaust gas 24
Explosion caused by lighting equipment 24
ACTIONS IF FIRE OCCURS 25
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 26
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 27
About DEF 27
PRECAUTIONS FOR DEF 28
General character and precautions for handling 28
Precautions for adding 28
Precautions for storing 28
Precautions for fire hazard and leakage 28
The other precautions 29
STORE AdBlue/DEF 30
Handling AdBlue/DEF in cold weather 30
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 31
Select an appropriate workplace 31
Disassembly and maintenance work in the field 31
Sealing of openings (prevention of flowing out of oil) 31
Preventing intrusion of foreign materials during refilling 32
Replacing hydraulic oil while its temperature is high 32
Avoid reusing the hydraulic oil and lubricating oil 32
Flushing operation 33
Cleaning operation 33
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 34
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 45
Defective contact of connectors (defective contact between male and female connectors) 45
Defective crimping or soldering of connectors 46
Disconnection in wiring 46
Water entering the connector by high-pressure jetting 46
Entry of water, dirt, or dust when disconnecting a connector 46
Oil, mud, or dust stuck to connector 47
Select an appropriate workplace 48
Sealing the opening 48
How to clean parts when dirt is stuck 48
Precautions for replacing fuel filter cartridge 48
Select an appropriate workplace 49
Sealing the opening 49
PRACTICAL USE OF KOMTRAX 50
Merit of using KOMTRAX 50
How to make a full use of KOMTRAX 51
How to operate KOMTRAX 51
Disconnecting connectors 52
Connecting connectors 53
Drying wiring harness 55
Handling controller 56
Method for disconnecting Deutsch connector 57
Method for connecting Deutsch connector 57
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 58
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 58
Method for disconnecting slide lock type connector (FRAMATOME-24) 58
Method for connecting slide lock type connector (FRAMATOME-24) 58
Method for disconnecting connector with lock to pull 59
Method for connecting connector with lock to pull 59
Method for disconnecting connector with lock to push (BOSCH-3) 60
Method for connecting connector with lock to push (BOSCH-3) 60
Method for disconnecting connector with lock to push (AMP-3) 61
Method for connecting connector with lock to push (AMP-3) 61
Method for disconnecting connector with lock to push (SUMITOMO-3) 61
Method for connecting connector with lock to push (SUMITOMO-3) 61
Method for disconnecting connector with lock to push (SUMITOMO-4) 61
Method for connecting connector with lock to push (SUMITOMO-4) 61
Method for disconnecting connector with housing to rotate 62
Method for connecting connector with housing to rotate 62
Method for connecting ring terminals and strip fuses to power stud of printed circuit boards 63
HOW TO READ ELECTRICAL WIRE CODE 64
TYPE, SYMBOL, AND MATERIAL 64
COLOR CODES TABLE 65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 66
STANDARD DIMENSION AND TOLERANCE 66
STANDARD CLEARANCE AND STANDARD VALUE 67
STANDARD INTERFERENCE 67
REPAIR LIMIT AND ALLOWABLE VALUE OR ALLOWABLE DIMENSION 67
ALLOWABLE CLEARANCE 68
ALLOWABLE INTERFERENCE 68
STANDARD TIGHTENING TORQUE TABLE 69
CONVERSION TABLE 77
METHOD OF USING THE CONVERSION TABLE 77
EXAMPLES OF USING THE CONVERSION TABLE TO CONVERT A UNIT FROM MM TO IN 77
TEMPERATURE 81
SPECIFICATIONS 83
DIMENSIONS, WEIGHTS AND OPERATING DATA 84
SPECIFICATIONS 86
WEIGHT TABLES 87
LUBRICANTS AND OPERATING MEDIUMS 88
BASIC PROCEDURES OF MAINTENANCE 90
OIL 90
FUEL 90
COOLANT 91
GREASE 91
STORING OIL AND FUEL 91
FILTERS 92
OUTLINE OF ELECTRIC SYSTEM 92
TIGHTENING TORQUE LIST – METRIC SCREWS AND NUTS 93
STRUCTURE AND FUNCTION 97
ABBREVIATION LIST 101
List of abbreviations used in the text 101
List of abbreviations used in the circuit diagrams 106
UREA SCR SYSTEM 107
UREA SCR SYSTEM DIAGRAM 109
FUNCTION OF UREA SCR SYSTEM 110
FUNCTION OF AdBlue/DEF SYSTEM 111
AdBlue/DEF INJECTION FUNCTION 111
AdBlue/DEF PURGE FUNCTION 112
FUNCTION OF AdBlue/DEF THAWING AND PREVENTING FROM FREEZING 112
INDUCEMENT STRATEGY 113
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BECOMES LOW 113
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF QUALITY OR IN THE UREA SCR SYSTEM DEVICES 115
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE DPF SYSTEM BY THE UREA SCR SYSTEM DEVICES 116
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYSTEM BY THE UREA SCR SYSTEM DEVICES 118
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40 HOURS 120
COMPONENT PARTS OF UREA SCR SYSTEM 121
Structure of AdBlue/DEF mixing tube 121
Function of AdBlue/DEF mixing tube 121
SCR ASSEMBLY 122
Structure of SCR assembly 122
AdBlue/DEF TANK 123
AdBlue/DEF TANK SENSOR 124
Structure of AdBlue/DEF tank sensor 124
Function of AdBlue/DEF tank sensor 124
AdBlue/DEF PUMP 125
Structure of AdBlue/DEF pump 125
AdBlue/DEF INJECTOR 126
Structure of AdBlue/DEF injector 126
Function of AdBlue/DEF injector 126
Operation of AdBlue/DEF injector 126
AdBlue/DEF HOSE 127
Structure of AdBlue/DEF hose 127
Function of AdBlue/DEF hose 127
AdBlue/DEF TANK HEATING VALVE 128
Structure of AdBlue/DEF tank heating valve 128
Function of AdBlue/DEF tank heating valve 128
Operation of AdBlue/DEF tank heating valve 129
ELECTRICAL SYSTEM 130
BOOT-UP SYSTEM 131
LAYOUT DRAWING OF BOOT-UP SYSTEM 131
AROUND THE CAB AND FLOOR 132
BATTERY DISCONNECT SWITCH 133
FUNCTION OF BATTERY DISCONNECT SWITCH 133
PREHEATING SYSTEM 135
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 135
OPERATION OF AUTOMATIC PREHEATING SYSTEM 136
ENGINE SYSTEM 137
LAYOUT DRAWING OF ENGINE SYSTEM 137
COOLING SYSTEM 138
LAYOUT DRAWING OF COOLING SYSTEM 138
SPECIFICATIONS OF COOLING SYSTEM 139
COOLING FAN CONTROL SYSTEM 140
FUNCTION OF COOLING FAN CONTROL SYSTEM 141
COOLING FAN REVERSE ROTATION FUNCTION (Option) 141
COMPONENT PARTS OF COOLING SYSTEM 142
STRUCTURE OF COOLING FAN MOTOR 142
CONTROL SYSTEM 143
AROUND THE CAB AND FLOOR 144
MACHINE MONITOR SYSTEM 145
MACHINE MONITOR SYSTEM DIAGRAM 145
KOMTRAX SYSTEM 146
KOMTRAX SYSTEM DIAGRAM 146
FUNCTION OF KOMTRAX SYSTEM 146
COMPONENT PARTS OF CONTROL SYSTEM 147
MACHINE MONITOR 147
Function of KOMTRAX terminal 160
HST CONTROLLER 162
Structure of HST controller 162
Real time monitoring function 162
Self-diagnosis function 162
Structure of HST controller (Creep DA Option) 168
Real time monitoring function 168
Self-diagnosis function 168
CAN TERMINATING RESISTOR 172
Function of CAN terminating resistor 172
ENGINE CONTROLLER 173
Real time monitoring function 173
Self-diagnosis function 173
ACCELERATOR PEDAL 174
Acceleration signal 174
Idling validation signal 174
Output Characteristics 175
HYDRAULIC SYSTEM 176
Structure of hydraulic tank 177
Specifications of hydraulic tank 177
Structure of main control valve 179
OPTIONAL HYDRAULIC SYSTEMS 182
Structure of the high flow system 182
Function of the high flow system 183
Structure of the 4th hydraulic circuit 184
Function of the 4th hydraulic circuit 185
POWER TRAIN SYSTEM 189
OPERATION OF POWER TRAIN SYSTEM 190
FUNCTION OF THE CLOSED CIRCUIT SYSTEM 192
SPECIFICATIONS OF THE HST SYSTEM 192
STRUCTURE OF THE HST SYSTEM 193
20km/h STD DA (with and without Speed Control) 193
20km/h or 40km/h with Speed Control and ET Pump 194
COMPONENT PARTS OF POWER TRAIN SYSTEM 195
Structure of drive shaft 195
Function of drive shaft 195
Structure of HST pump 196
Operation of HST pump 198
Components of HST pump 199
HST motor 203
Structure of transfer box 205
Function of transfer box 206
Structure of front axle 207
Structure of rear axle 208
Function of differential 210
Function of towing system 212
WORK EQUIPMENT SYSTEM 213
Layout of work equipment system 213
WORK EQUIPMENT LOCK SYSTEM 215
ECSS 216
Function of ECSS 216
Operation of ECSS 216
RETURN TO DIG (option) 217
Structure 217
Function 217
Main control valve 218
EPC valve 218
PPC accumulator 218
PPC valve 219
Structure 219
Function 220
Operation 220
Loader Linkage with quick-coupler 221
STEERING SYSTEM 223
STEERING COLUMN 224
Structure of steering column 224
General view 224
PRIORITY VALVE 227
ORBIT-ROLL-VALVE 228
STEERING RELIEF VALVE 229
BRAKE SYSTEM 230
LAYOUT DRAWING OF BRAKE SYSTEM 230
SERVICE BRAKE ASSEMBLY 231
Function 231
PARKING BRAKE ASSEMBLY 232
STRUCTURE OF BRAKE SYSTEM 233
20km/h with DA pump 233
20km/h or 40km/h with ET pump 234
UNDERCARRIAGE AND FRAME 235
Rear axle mount 236
FRAME, AXLE MOUNT AND CENTER HINGE PIN 237
TIRE 238
Structure of radial tire 238
General view 238
Structure 238
Structure of bias tire 239
General view 239
Structure 239
WORK EQUIPMENT 240
STRUCTURE OF WORK EQUIPMENT 240
STRUCTURE OF BUCKET 241
General view and sectional view 241
CAB AND ITS ATTACHMENTS 242
ROPS FOPS CAB 242
Structure of ROPS FOPS cab 242
Function of ROPS FOPS cab 243
CAB MOUNT 244
Structure of cab mount 244
General view 244
Function of cab mount 244
STANDARD VALUE TABLE 255
ABBREVIATION LIST 256
List of abbreviations used in the text 256
List of abbreviations used in the circuit diagrams 261
STANDARD VALUE TABLE 262
Standard value table for engine 262
Standard value table for chassis 263
TEST CERTIFICATE 265
TESTING AND ADJUSTING 267
ABBREVIATION LIST 271
List of abbreviations used in the text 271
List of abbreviations used in the circuit diagrams 276
TEST ENGINE WITH SOFTWARE TOOL 277
CONNECTION OF A COMPUTER TO THE MACHINE 277
ENGINE AND COOLING SYSTEM 279
TEST ENGINE SPEED 279
Method for testing engine speed 279
Method for testing engine low idle speed 279
Method for testing engine high idle speed 280
Method for testing engine speed HST stall 281
Method for testing engine speed at hydraulic stall 282
Method for testing engine speed at full stall (HST stall and hydraulic stall) 283
TEST EXHAUST GAS COLOUR 284
Testing tool for exhaust gas colour 284
METHOD FOR TESTING EXHAUST GAS COLOUR BY HANDY SMOKE CHECKER 285
TEST AND ADJUST VALVE CLEARANCE 286
METHOD FOR TESTING AND ADJUSTINGVALVE CLEARANCE 287
TEST COMPRESSION PRESSURE 290
METHOD FOR TESTING COMPRESSION PRESSURE 291
Compression pressure inspection procedures 291
Injector reassembly procedures 293
TEST ENGINE OIL PRESSURE 296
METHOD FOR TESTING ENGINE OIL PRESSURE 296
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 298
TEST FUEL CIRCUIT FOR LEAKAGE 299
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 299
Testing method of fuel circuit for leakage at engine stopped 299
Testing method of fuel circuit for leakage at engine low idle 300
Testing method of fuel circuit for leakage at engine high idle 300
HANDLE NO-INJECTION CRANKING OPERATION 301
TEST DOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 302
METHOD FOR TESTING DOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 302
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 303
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 303
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 304
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 304
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 305
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 305
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 306
TEST ALTERNATOR BELT 307
METHOD FOR TESTING ALTERNATOR BELT 307
CLEAN AdBlue/DEF TANK 308
METHOD FOR CLEANING AdBlue/DEF TANK 308
POWER TRAIN 312
TEST AND ADJUST HST PRESSURE CUT OFF 312
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 314
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 314
STEERING SYSTEM 315
Operating time for steering wheel 315
Operating force of steering wheel 316
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 316
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 317
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 318
BLEED AIR FROM STEERING CYLINDER CIRCUIT 319
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 319
BLEED AIR FROM BRAKE CIRCUIT 320
TEST BRAKING PERFORMANCE 322
MEASURING THE STOPPING DISTANCE 322
TEST AND ADJUST BRAKE PEDAL 323
TEST WEAR OF WHEEL BRAKE DISC 324
TEST PARKING BRAKE PERFORMANCE 325
HYDRAULIC SYSTEM 326
Releasing the remaining pressure in ECSS 327
TEST AND ADJUST WORK EQUIPMENT PRESSURE 328
TEST WORK EQUIPMENT PPC PRESSURE 329
BLEED AIR FROM WORK EQUIPMENT PPC CIRCUIT 330
TESTING AND ADJUSTING COOLING FAN SPEED 331
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE 333
METHOD FOR TESTING THE ECSS ACCUMULATOR NITROGEN GAS PRESSURE 334
METHOD FOR CHARGING THE ECSS ACCUMULATOR WITH NITROGEN GAS 335
ELECTRICAL SYSTEM 337
SET AND ADJUST EACH EQUIPMENT 337
SET AND OPERATE MACHINE MONITOR 338
Switch panel 338
OPERATOR MODE 341
Setting usage limitation (password) 341
Change password 342
SERVICE MODE 344
Table of self-define monitoring 347
ABNORMALITY RECORD MENU 360
DEFAULT MENU 371
ADJUSTMENT MENU 376
HANDLE BATTERY DISCONNECT SWITCH 379
TEST DIODES 382
TROUBLESHOOTING 385
ABBREVIATION LIST 389
List of abbreviations used in the text 389
List of abbreviations used in the circuit diagrams 394
RELATED INFORMATION ON TROUBLESHOOTING 395
GENERAL TROUBLESHOOTING POINTS 395
SEQUENCE OF EVENTS IN TROUBLESHOOTING 397
CHECKS BEFORE TROUBLESHOOTING 399
Engine, lubricating oil, coolant, and AdBlue/DEF 399
Hydraulic and mechanical equipment 399
Electric equipment 400
Exterior 400
Interior 400
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 401
WALK-AROUND CHECK 401
PROCEDURE FOR TESTING AND TROUBLESHOOTING 403
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 404
CONNECTOR LOCATION LIST 406
CONNECTOR CONTACT IDENTIFICATION 415
SPARE FUSES AND RELAY 452
USB socket on central electric board (CEB) 457
FAILURE CODES TABLE 460
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF HST-CONTROLLER CODE) 486
POWER ON 487
8 2 1 Documentation of Power On (PwrOn) 487
8 2 1 – 2 Interface 487
8 2 1 – 3 Description 488
8 2 1 – 3 3 State 2: Check sensor supply voltages 491
8 2 1 – 3 4 State 3: Check hardware monitoring errors 491
8 2 1 – 3 5 State 4: Check first application specific start condition 491
8 2 1 – 3 6 State 5: Check central switch 491
8 2 1 – 3 7 State 6: Configure safouts 492
8 2 1 – 3 8 State 7: Check safouts 492
8 2 1 – 3 9 State 8: Check diesel engine speed 492
8 2 1 – 3 10 State 9: Enable sensor supply monitoring 493
8 2 1 – 3 11 State 10: Check hardware monitoring errors 493
8 2 1 – 3 12 State 11: Check second applications specific start condition 493
8 2 1 – 3 12 State 11: Check second applications specific start condition 493
8 2 1 – 3 13 State 12: Run 493
8 2 1 – 3 14 Diagnosis Configuration Notes 494
8 2 1 – 4 Input Signals 494
8 2 1 – 5 Parameters 495
8 2 1 – 6 Output Signals 495
8 2 1 – 7 Error Information 495
Abbreviations for Failure Code (HST-controller) 497
FAILURE CODE (#R0CIB) 498
FAILURE CODE (#R0CKB) 499
FAILURE CODE (#R0CLB) 500
FAILURE CODE (#R0CMB) 501
FAILURE CODE (#R0CPV) 502
FAILURE CODE (#R0CQB) 503
FAILURE CODE (#R0CRB) 504
FAILURE CODE (#R0CSB) 505
FAILURE CODE (#R0CTB) 506
FAILURE CODE (#R0CWB) 507
FAILURE CODE (#R0JLB) 508
FAILURE CODE (#R0JMB) 509
FAILURE CODE (#R0JNB) 510
FAILURE CODE (#R0JOB) 511
FAILURE CODE (#R0JPB) 512
FAILURE CODE (#R0QR2) 513
FAILURE CODE (#R0QS2) 514
FAILURE CODE (#R0QT4) 515
FAILURE CODE (#R0QU3) 516
FAILURE CODE (#R0QV4) 517
FAILURE CODE (#R0QY4) 518
FAILURE CODE (#R0QZ4) 519
FAILURE CODE (#R0R0V) 520
FAILURE CODE (#R0R1V) 521
FAILURE CODE (#R0SHV) 522
FAILURE CODE (#R0SIV) 523
FAILURE CODE (#R0SJV) 524
FAILURE CODE (#R0SKV) 525
FAILURE CODE (#R0SLV) 526
FAILURE CODE (#R0XU2) 527
FAILURE CODE (#R0XU3) 528
FAILURE CODE (#R0XU4) 529
FAILURE CODE (#R0XUB) 530
FAILURE CODE (#R0XV2) 531
FAILURE CODE (#R0XV3) 532
FAILURE CODE (#R0XV4) 533
FAILURE CODE (#R0XVB) 534
FAILURE CODE (#R0XW2) 535
FAILURE CODE (#R0XW3) 536
FAILURE CODE (#R0XW4) 537
FAILURE CODE (#R0XWB) 538
FAILURE CODE (#R0XY2) 539
FAILURE CODE (#R0XY3) 540
FAILURE CODE (#R0XY4) 541
FAILURE CODE (#R0XYB) 542
FAILURE CODE (#R14W2) 543
FAILURE CODE (#R14WB) 544
FAILURE CODE (#R14X2) 545
FAILURE CODE (#R14XB) 546
FAILURE CODE (#R14Y2) 547
FAILURE CODE (#R14YB) 548
FAILURE CODE (#R14Z2) 549
FAILURE CODE (#R14ZB) 550
FAILURE CODE (#R1502) 551
FAILURE CODE (#R1504) 552
FAILURE CODE (#R150B) 553
FAILURE CODE (#R1512) 554
FAILURE CODE (#R151B) 555
FAILURE CODE (#R15C2) 556
FAILURE CODE (#R15C3) 557
FAILURE CODE (#R15C4) 558
FAILURE CODE (#R15CB) 559
FAILURE CODE (#R15CV) 560
FAILURE CODE (#R1KWJ) 561
FAILURE CODE (#R1KWV) 562
FAILURE CODE (#R1QB2) 563
FAILURE CODE (#R1QBB) 564
FAILURE CODE (#R1QBV) 565
FAILURE CODE (#R1QD2) 566
FAILURE CODE (#R1QDB) 567
FAILURE CODE (#R1QE2) 568
FAILURE CODE (#R1QEB) 569
FAILURE CODE (#R1QEV) 570
FAILURE CODE (#R1XEB) 571
FAILURE CODE (#R1XFB) 572
FAILURE CODE (#R1XG2) 573
FAILURE CODE (#R1XGB) 574
FAILURE CODE (#R1XJB) 575
FAILURE CODE (#R20XB) 576
FAILURE CODE (#R20YB) 577
FAILURE CODE (#R268B) 578
FAILURE CODE (#R2693) 579
FAILURE CODE (#R2694) 580
FAILURE CODE (#R2695) 581
FAILURE CODE (#R269B) 582
FAILURE CODE (#R26AB) 583
FAILURE CODE (#R26B3) 584
FAILURE CODE (#R26B4) 585
FAILURE CODE (#R26B5) 586
FAILURE CODE (#R26BB) 587
FAILURE CODE (#R26OB) 588
FAILURE CODE (#R26P3) 589
FAILURE CODE (#R26P4) 590
FAILURE CODE (#R26P5) 591
FAILURE CODE (#R26PB) 592
FAILURE CODE (#R280B) 593
FAILURE CODE (#R2813) 594
FAILURE CODE (#R2814) 595
FAILURE CODE (#R2815) 596
FAILURE CODE (#R281B) 597
FAILURE CODE (#R2BKB) 598
FAILURE CODE (#R2J92) 599
FAILURE CODE (#R2J9V) 600
FAILURE CODE (#R2JK2) 601
FAILURE CODE (#R2JK9) 602
FAILURE CODE (#R2JKB) 603
FAILURE CODE (#R2JL2) 604
FAILURE CODE (#R2JL9) 605
FAILURE CODE (#R2JLB) 606
FAILURE CODE (#R2JM2) 607
FAILURE CODE (#R2JM9) 608
FAILURE CODE (#R2JMB) 609
FAILURE CODE (#R2JN2) 610
FAILURE CODE (#R2JN9) 611
FAILURE CODE (#R2JNB) 612
FAILURE CODE (#R2JO2) 613
FAILURE CODE (#R2JO9) 614
FAILURE CODE (#R2JOB) 615
FAILURE CODE (#R2JP2) 616
FAILURE CODE (#R2JP9) 617
FAILURE CODE (#R2JPB) 618
FAILURE CODE (#R2JR2) 619
FAILURE CODE (#R2JR9) 620
FAILURE CODE (#R2JRB) 621
FAILURE CODE (#R2JS2) 622
FAILURE CODE (#R2JS9) 623
FAILURE CODE (#R2JSB) 624
FAILURE CODE (#R2JT2) 625
FAILURE CODE (#R2JT9) 626
FAILURE CODE (#R2JTB) 627
FAILURE CODE (#R2JU2) 628
FAILURE CODE (#R2JU9) 629
FAILURE CODE (#R2JUB) 630
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E- MODE) 631
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 650
TROUBLESHOOTING OF ENGINE (S-MODE) 659
S-4 ENGINE STARTABILITY IS POOR 663
S-9 EXHAUST SMOKE IS BLACK 671
S-12 FUEL CONSUMPTION IS EXCESSIVE 675
S-14 OIL PRESSURE DROPS 677
S-18 UNUSUAL NOISE IS HEARD 681
S-19 VIBRATION IS EXCESSIVE 682
DISASSEMBLY AND ASSEMBLY 689
ABBREVIATION LIST 691
List of abbreviations used in the text 691
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 696
HOW TO READ THIS MANUAL 696
Reading the work procedures 696
Reading the symbols 696
Reading the signal word 697
Reading the unit 697
COATING MATERIALS LIST 698
Adhesive 698
Liquid gasket 699
Molybdenum disulfide lubricant 699
Seizure prevention compound 700
Grease 700
Primer 701
Adhesive 701
Caulking material 701
ENGINE AND COOLING SYSTEM 702
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 702
Removal of supply pump assembly 702
Reassembly of supply pump 704
REMOVE AND INSTALL INJECTOR ASSEMBLY 706
Removal of injector 706
Reassembly of injector 707
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 710
Disassembly of Cylinder Head 710
Cleaning of cylinder head components 721
Inspection of cylinder head components 722
Reassembly of cylinder head 728
REMOVE AND INSTALL EGR VALVE ASSEMBLY 735
Remove and install EGR cooler assembly 735
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 736
Removal of Starter Motor 736
Disassembly of Starter Motor 736
Reassembly of Starter Motor 739
Reassembly of Starter Motor 740
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 741
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 741
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 744
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 748
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 748
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 750
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 757
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 757
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 758
REMOVE AND INSTALL DOC and SCR ASSEMBLY 759
METHOD FOR REMOVING DOC ASSEMBLY 760
REMOVE AND INSTALL AdBlue/DEF INJECTOR 770
Method for removing AdBlue/ DEF injector 772
Method for installing AdBlue/DEF injector 774
REMOVE AND INSTALL AdBlue/DEF PUMP 776
Method for removing AdBlue/DEF pump 776
Method for installing AdBlue/DEF pump 779
REMOVE AND INSTALL AdBlue/DEF HOSE 781
Method for removing AdBlue/DEF hose 781
POWER TRAIN 788
PUMP FOR STEERING, WORK EQUIPMENT, COOLING FAN AND HIGH FLOW 788
Removal of the standard pump (steering, work equipment and cooling fan) 788
Removal of the HighFlow pump (steering, work equipment, cooling fan and HighFlow) 788
Installation of hydraulic pump assembly (standard and high flow) 789
ARTICULATED JOINT ASSEMBLY 790
Removal of articulation joint assembly 790
Installation of articulation joint assembly 790
HST MOTOR ASSEMBLY 791
Removal of HST motor assembly 791
Installation of variable motor assembly 792
HST PUMP ASSEMBLY 793
Removal of HST pump assembly 793
Installation of HST pump assembly 794
GEARBOX (TRANSFER ASSEMBLY) 795
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY 795
Safety precautions 795
HYDRAULIC GEAR CONTROL 796
Exploded view 796
Disassembly 797
Assembly 800
HYDRAULIC GEAR CONTROL – VALVE ON BOARD 805
Exploded view 805
Disassembly 806
Assembly 809
HYDRAULIC GEAR CONTROL (CONTACTLESS SENSOR) 815
Exploded view 815
Disassembly 816
Assembly 820
COUNTER-REVOLUTION SENSOR 826
Replacement 826
SHORT FLANGED REDUCTION GEAR 827
Exploded view 827
Disassembly 828
Assembly 836
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 849
REMOVE AND INSTALL ALTERNATOR BELT 850
GEARBOX INSTALLATION 851
Disassembly 851
INTEGRATED GEAR BOX 854
Exploded view 854
Disassembly 855
Assembly 862
REMOVE AND INSTALL ALTERNATOR ASSEMBLY 871
SPECIAL TOOLS 872
REAR AXLE ASSEMBLY 875
Removal of rear axle assembly 875
Installation of rear axle assembly 877
FRONT AXLE ASSEMBLY 878
Removal of front axle assembly 878
Installation of front axle assembly 879
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS 880
SAFETY PRECAUTIONS 880
CHECKING WEAR AND REPLACING THE BRAKING DISCS 881
Exploded view 881
Disassembly 882
Assembly 884
Special tools 886
DISASSEMBLY AND ASSEMBLY AXLE HOUSING ASSEMBLY 887
PLANETARY REDUCTION AND AXLE SHAFT 887
Exploded view 887
Disassembly 888
Assembly 892
Special tools 896
BEVEL PINION 899
Exploded view 899
Disassembly 900
Assembly 902
Special tools 909
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY 915
DIFFERENTIAL UNIT 915
Exploded view 915
Disassembly 916
Assembly 918
Special tools 920
MANUAL EMERGENCY RELEASE 921
Exploded view 921
Release 922
Adjustment 923
MECHANICAL PARKING BRAKE 924
Exploded view 924
Disassembly 925
Assembly 927
NORMAL DIFFERENTIAL UNIT 929
Exploded view 929
Disassembly 930
Assembly 932
Special tools 935
LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) 938
Exploded view 938
Disassembly 939
Assembly 942
Special tools 945
HYDRAULIC DIFFERENTIAL LOCK 948
Exploded view 948
Disassembly 949
Assembly 952
Special tools 954
WORK EQUIPMENT SYSTEM 955
REMOVE AND INSTALL MAIN VALVE ASSEMBLY 955
Removal of main control valve assembly 955
Installation of main control valve assembly 956
REMOVE AND INSTALL PILOT VALVE ASSEMBLY 957
Removal of pilot control valve assembly 957
Removal of standard multifunction lever 959
Removal of optional multifunction lever 960
Assembly of pilot control valve 960
ELECTRICAL SYSTEM 962
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 962
Remove and install central electric board (CEB) 962
Method for removing engine controller assembly 963
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 965
Method for removing the cover of the console 965
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 966
Method for removing machine monitor assembly 966
Method for installing machine monitor assembly 969
REMOVE AND INSTALL EPC CONTROLLER ASSEMBLY 970
Method for removing the cover of the console 970
MAINTENANCE STANDARD 971
ABBREVIATION LIST 973
List of abbreviations used in the text 973
List of abbreviations used in the circuit diagrams 978
ENGINE AND COOLING 979
MAINTENANCE STANDARD OF ENGINE MOUNT 979
MAINTENANCE STANDARD OF DAMPER 980
MAINTENANCE STANDARD OF COOLING FAN MOTOR 981
HYDRAULIC SYSTEM 982
CAB AND ITS ATTACHMENTS 986
Cabin – adjustment 986
APPENDIX 987
ABBREVIATION LIST 989
List of abbreviations used in the text 989
List of abbreviations used in the circuit diagrams 994
AIR CONDITIONER SYSTEM 995
PRECAUTIONS FOR REFRIGERANT 995
AIR CONDITIONER COMPONENT 996
Specifications of air conditioner 996
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 997
OUTLINE OF REFRIGERATION CYCLE 998
Compression (Compressor) 998
Condensation (Condenser) 998
Expansion (Expansion valve) 998
Evaporation (Evaporator) 999
Relation between refrigerant and cooling trouble 999
AIR CONDITIONER TROUBLESHOOTING CHART 1001
Cooling trouble 1001
Heating trouble 1001
CONNECTION OF SERVICE TOOL 1002
METHOD FOR CONNECTING SERVICE TOOL 1003
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 1004
Precautions for disconnection 1004
Precautions for connection 1005
HANDLE COMPRESSOR OIL 1006
Management of compressor oil (SANDEN: SP-10 for use with R134a) 1006
Filling of compressor oil 1006
The quantity of compressor oil when the compressor is replaced 1007
OTHER 1009
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NUMBERS: H11840 – AND UP) 1013
WIRING DIAGRAMS (SERIAL NUMBERS: H11840 – AND UP) 1015
Contents 1015
1-0 SYMBOLS SUMMARY, ABBREVIATIONS 1016
1-1 HARNESS ARRANGEMENT EXPLANATION 1017
1-2 CAN BUS SUMMARY 1018
2-0 POWER SUPPLY, STARTER SWITCH 1019
2-1 GROUNDING 1020
2-2 RELAYB , STARTER, ALTERN , BATTERY, GLOW PLUG0 1021
2-3 DEF & ECU RELAYS 1022
3-0 AFTERTREATMENT SYSTEM 1023
3-1 ECU, AIR CLEANER, WATER SEPA , FUEL FEED PUMP 1024
3-2 DPF SENS , OIL PRESS , TRAVEL PED , HEATER LINES 1025
4-0 MONITOR, MAIN CONTROLLER, STEERING PRESSURE 1026
4-1 KOMTRAX CTRL, SERVICE CONNECTOR 1027
4-2 FLUID-SENSORS (OIL, FUEL, COOLANT), SPEED SENS 1028
5-0 SEC ENG STOP, IMMOBILIZER, DRIVING FUNCT 1029
5-1 SPEED CONTROLLER 40KPH 1030
5-2 HST CONTROLLER INPUTS 1031
5-3 CREEP, HIGH FLOW 1032
6-0 FAN DRIVE, REVERSE FAN 1033
7-0 AIR CONDITIONER, OPERATORS SEATI 1034
7-1 WASHER, WIPER, REAR WINDOW HEATER, HORN 1035
8-0 LIGHTING 1036
8-1 FLASHER 1037
8-2 REAR LIGHT, LICENSE PL , BACKUP AL , REAR FLASH 1038
8-3 WORK LAMPS 1039
8-4 INTERIOR LAMP, ROTATING BEACON, PLUG BOX 1040
9-0 3RD AND 4TH HYDRAULIC CIRCUIT EPC INPUT 1041
9-1 3RD AND 4TH HYDRAULIC CIRCUIT EPC OUTPUT 1042
10-0 DRIVING RANGE, ECSS, OVER CENTER V , AUTO INCH 1043
10-1 RETURN TO DIG, QUICK COUPLER, DIFF LOCK 1044
10-2 RADIO, CLS, BLANK OPT , DPF REGEN SW, MAINT SW 1045
10-3 CREEP SC DA 1046
11-0 ADDITIONAL OPTIONS 1047
W1 WIRING HARNESS LIST 1048
W2 CONNECTOR LIST 1 1049
W2 CONNECTOR LIST 2 1050
W2 CONNECTOR LIST 3 1051
W2 CONNECTOR LIST 4 1052
W2 CONNECTOR LIST 5 1053
W2 CONNECTOR LIST 6 1054
W3 PIN LOCATION LIST 1 1055
W3 PIN LOCATION LIST 2 1056
W3 PIN LOCATION LIST 3 1057
W3 PIN LOCATION LIST 4 1058
W3 PIN LOCATION LIST 5 1059
W3 PIN LOCATION LIST 6 1060
W3 PIN LOCATION LIST 7 1061
W3 PIN LOCATION LIST 8 1062
W3 PIN LOCATION LIST 9 1063
W3 PIN LOCATION LIST 10 1064
W3 PIN LOCATION LIST 11 1065
W3 PIN LOCATION LIST 12 1066
W3 PIN LOCATION LIST 13 1067
W3 PIN LOCATION LIST 14 1068
W3 PIN LOCATION LIST 15 1069
W3 PIN LOCATION LIST 16 1070
W3 PIN LOCATION LIST 17 1071
W3 PIN LOCATION LIST 18 1072
W3 PIN LOCATION LIST 19 1073
W3 PIN LOCATION LIST 20 1074
W3 PIN LOCATION LIST 21 1075
W3 PIN LOCATION LIST 22 1076
W3 PIN LOCATION LIST 23 1077
W3 PIN LOCATION LIST 24 1078
W3 PIN LOCATION LIST 25 1079
W3 PIN LOCATION LIST 26 1080
W3 PIN LOCATION LIST 27 1081
W3 PIN LOCATION LIST 28 1082
W3 PIN LOCATION LIST 29 1083
W3 PIN LOCATION LIST 30 1084
W3 PIN LOCATION LIST 31 1085
W3 PIN LOCATION LIST 32 1086
W3 PIN LOCATION LIST 33 1087
W3 PIN LOCATION LIST 34 1088
W3 PIN LOCATION LIST 35 1089
W3 PIN LOCATION LIST 36 1090
W3 PIN LOCATION L IST 37 1091
W3 PIN LOCATION L IST 38 1092
PARTS LIST 1 1093
PARTS LIST 2 1094
PARTS LIST 3 1095
Connector diagram 1097
Connector diagram 1 1097
Connector diagram 2 1098
Connector diagram 3 1099
Connector table for the operator‘s cab wiring harness (Part 1/2) 1099
Connector diagram 4 1100
Connector table for operator‘s cab wiring harness (Part 2/2) 1100

DESCRIPTION:

Komatsu WA100M-8E0 Wheel Loader Shop Manual VENBM07004 – PDF DOWNLOAD 

Model:              Serial number:
WA100M-8E0   H11840 AND UP

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

S.V 30/12/24