Thisshopmanualmaycontainattachmentsandoptionalequipmentthatarenotavailableinyourarea. PleaseconsultyourlocalKOMATSUdistributorforthoseitemsyoumayrequire.
Materialsandspecificationsaresubjecttochangewithoutnotice.
TheWheelLoaderWA100M-8E0isequippedwiththeengineSAA4D94LE-3.
FordetailsofthisengineseeEngineManual:WA100M-8inattachment.
PRECAUTIONSFORHANDLINGELECTRICALEQUIPMENT...................................0-43
PRECAUTIONSFORDISCONNECTIONANDCONNECTIONOFCONNECTORS................0-50
PRECAUTIONSFORTROUBLESHOOTINGELECTRICALCIRCUITS..........................0-54
METHODFORDISCONNECTINGANDCONNECTINGDEUTSCHCONNECTOR................0-55
METHODFORDISCONNECTINGANDCONNECTINGSLIDELOCKTYPECONNECTOR.........0-56
METHODFORDISCONNECTINGANDCONNECTINGCONNECTORWITHLOCKTOPULL.......0-57
METHODFORDISCONNECTINGANDCONNECTINGCONNECTORWITHLOCKTOPUSH......0-58
METHODFORDISCONNECTINGANDCONNECTINGCONNECTORWITHHOUSINGTOROTATE.0-60
HOWTOREADELECTRICALWIRECODE..................................................0-62
Thislistofabbreviationsincludestheabbreviationsusedin thetextoftheshopmanualforparts,components,andfunctionswhosemeaningisnotimmediatelyclear.Thespelling isgiveninfullwithanoutlineofthemeaning.
Abbreviationsthatareusedingeneralsocietymaynotbe included.
Specialabbreviationswhichappearinfrequentlyarenotedin thetext.
Thislistofabbreviationsconsistsoftwoparts.Thefirstpart isalistoftheabbreviationsusedinthetextofthemanual, andthesecondpartisalistoftheabbreviationsusedinthe circuitdiagrams.
Listofabbreviationsusedinthetext
Abbrevia-tionActualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
ABSAntilockBrakeSystemTravelandbrake (HD,HM)
AISSAutomaticIdlingSetting System Engine
AJSSAdvancedJoystick SteeringSystem Steering (WA)
ARACAutomaticRetarderAcceleratorControl
ARSCAutomaticRetarder SpeedControl
ASRAutomaticSpinRegulator
Travelandbrake (HD,HM)
Travelandbrake (HD,HM)
Travelandbrake (HD,HM)
Explanation
Thisisafunctionthatreleasesthebrakewhenthe tiresskid(tiresarenotrotated).Thisfunctionapplies thebrakeagainwhenthetiresrotate.
Thisisafunctionthatautomaticallysetstheidle speed.
Thisisafunctionthatperformsthesteeringoperationswithaleverinsteadofusingasteeringwheel. Thisfunctionperformsgearshiftingandchanging forwardandreversedirection.
Thisisafunctionthatautomaticallyoperatesthe retarderwithaconstantbrakingforcewhenletting gooftheacceleratorpedalonthedownhill.
Thisisafunctionthatautomaticallyoperatesthe retardertoensurethatthemachinespeeddoesnot accelerateabovethespeedsetbytheopera-tor whenlettinggooftheacceleratorpedalon thedownhill.
Thisisafunctionthatdrivesbothwheelsautomaticallyusingtheoptimumbrakingforcewhenthetire ononesidespinsonthesoftgroundsur-faces.
ATTAttachmentWorkequipmentAfunctionorcomponentthatcanbeaddedtothe standardspecification.
BCVBrakecoolingoilcontrol valve BRAKE (HD)
CANControllerAreaNetworkCommunicationandelectroniccontrol
CDRCrankcaseDepression Regulator Engine
CLSSClosed-centerLoadSensingSystemHydraulicsystem
Thisisavalvethatbypassesapartofthebrake coolingoiltoreducetheloadappliedtothehydraulic pumpwhentheretarderisnotbeingused.
Thisisoneofcommunicationstandardsthatare usedinthenetworkonthemachine.
ThisisaregulatorvalvethatisinstalledtoCCVventilator.ItiswrittenasCDRvalveandisnotused independently.
Thisisasystemthatcanactuatemultipleactuators simultaneouslyregardlessoftheload(providesbettercombinedoperationthanOLSS).
Abbrevia-tionActualwordspelledout
Purposeofuse(major applicablemachine(*1), orcomponent/system)
CRICommonRailInjectionEngine
ECMElectronicControl Module Electroniccontrolsystem
ECMVElectronicControl ModulationValve Transmission (D,HD,WA,etc)
ECSS ElectronicallyControlled SuspensionSystem Travel (WA)
ECUElectronicControlUnitElectroniccontrolsystem
EGRExhaustGasRecirculation Engine
EMMS EquipmentManagementMonitoringSystem Machinemonitor
EPCElectromagneticPro-portionalControlHydraulicsystem
FOPSFallingObjectProtec-tiveStructureCabandcanopy
Explanation
Thisisafunctionthatmaintainsoptimumfuel injectionamountandfuelinjectiontiming.This isperformedtheenginecontrollerwhichelectronicallycontrolssupplypump,commonrail, andinjector.
Thisisanelectroniccontroldevicethatsend thecommandtoactuatorsusingthesignals fromthesensorsonthemachinesothatthe optimumactuationisperformed.(Sameas
Thisisaproportionalelectromagneticvalve thatdecreasesthetransmissionshockbygraduallyincreasingoilpressureforengaging
Thisisadevicethatensuressmoothhighspeedtravelbyabsorbingvibrationofmachine duringtravelwithhydraulicspringeffectof
Thisisanelectroniccontroldevicethatsend thecommandtoactuatorsusingthesignals fromthesensorsonthemachinesothatthe optimumactuationisperformed.(Sameas
Thisisafunctionthatrecirculatesapartof exhaustgastocombustionchamber,sothatit reducescombustiontemperature,andreduces emissionofNOx.
Thisisafunctionwithwhichoperatorcan checkinformationfromeachsensoronthe machine(filter,oilreplacementinterval,malfunctionsonmachine,failurecode,andfailure
ElectromagneticproportionalcontrolThisisa mechanismwithwhichactuatorsoperatein proportiontothecurrent.
Thisstructureprotectstheoperator'sheadfrom fallingobjects.(Fallingobjectprotectivestructure)
ThisperformanceisstandardizedasISO3449.
F-N-RForward-Neutral-Reverse OperationForward-Neutral-Reverse
GPSGlobalPositioningSystem Communication (KOMTRAX,KOMTRAX Plus)
GNSSGlobalNavigationSatelliteSystem Communication (KOMTRAX,KOMTRAX Plus)
HSSHydrostaticSteering System Steering (DSeries)
HSTHydroStaticTransmission Transmission (D,WA)
Thissystemusessatellitestodeterminethe currentlocationontheearth.
Thisisageneraltermforsystemusessatellites suchasGPS,GALILEO,etc.
Thisisafunctionthatenablesthemachineto turnwithoutsteeringclutchbycontrollingadifferenceintravelspeedofrightandlefttracks withacombinationofhydraulicmotorand
Hydraulictransmissionsystemthatusesa combinationofhydraulicpumpandhydraulic motorwithoutusinggearsforsteplessgear
Abbrevia-tionActualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
ICTInformationandCommunicationTechnology Communicationandelectroniccontrol
IMAInletMeteringActuatorEngine
IMUInertialMeasurement Unit Engine
IMVInletMeteringValveEngine
CCVClosedCrankcase VentilationEngine
KCSFKomatsuCatalyzed SootFilterEngine
KDOCKomatsuDieselOxida-tionCatalystEngine
KDPFKomatsuDieselParticulateFilterEngine
KTCSKomatsuTractionControlSystem Travelandbrake (HM)
LCDLiquidCrystalDisplayMachinemonitor
Explanation
Ageneraltermfortheengineeringandits social-lyappliedtechnologyofinformationprocessingandcommunication.
Thisisavalvethatadjuststhefuelintake amountatthepumpinletinordertocontrolthe supplypumpfueldischargedvolume.(Same
Thisisadevicetodetecttheangle(orangular velocity)andaccelerationofthe3axesthat con-trolmotions.
Thisisavalvethatadjuststhefuelintake amountatthepumpinletinordertocontrolthe supplypumpcombustiondischargedvolume. (SameasIMA)
Thisisamechanismthatburnstheblowbygas againbyseparatingoilfromblowbygasandreturningittotheintakeside.Itprimarilyconsists offilters.
Thisisafilterthatcapturessootinexhaust gas.
Thisisacatalystthatisusedforpurifyingexhaustgas. ItisbuiltintoKDPForassembledwiththemuffler.
Thisisacomponentthatisusedtopurifythe ex-haustgas.KDOC(catalyst)andKCSF(filtertocapturesoot)arebuilt-init. Itisinstalledinsteadoftheconventionalmuffler.
Thisisafunctionthatperformsbrakingwiththe optimumforceandrecoversthedrivingforceof thewheelsbyactuatingtheinter-axledifferentiallockwhenthewheelsrunsidlewhilethe machinetravelsonthesoftground.
Thisisanimagedisplayequipmentsuchasa monitorinwhichtheliquidcrystalelementsare assembled.
LEDLightEmittingDiodeElectronicpartsThisisasemiconductorelementthatemitslight whenthevoltageisappliedinforwarddirection.
LINLocalInterconnectNetwork
Communicationandelectroniccontrol
LSLoadSensingHydraulicsystem
LVDSLowVoltageDifferential
Communicationandelectroniccontrol
MAFMassAirFlowEngine
Thisisoneofcommunicationstandardsthat areusedinthenetworkonthemachine.
Thisisafunctionthatdetectsdifferentialpressureofpump,andcontrolsdischargedvolume correspondingtoload.
Thisisoneofcommunicationstandardsthat areusedinthenetworkonthemachine.
Thisindicatesengineintakeairflow.Thisisnot usedindependentlybutisusedascombined withsensor.Massairflowsensorcanbecalled asMAFsensor.
Abbrevia-tionActualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
MMSMultimediaMessaging Service Communication
NCNormallyClosedElectricalsystem,hydraulicsystem
NONormallyOpenElectricalsystem,hydraulicsystem
OLSSOpen-centerLoadSensingSystemHydraulicsystem
Explanation
Thisisaservicethatallowstransmissionand receptionofshortmessagesconsistingofcharactersorvoiceorimagesbetweencellphones.
Thisisacharacteristicofelectricalorhydraulic circuits.Circuitisnormallyclosedifitisnot actuated,anditopenswhenitisactuated.
Thisisacharacteristicofelectricalorhydraulic circuits.Circuitisnormallyopenifitisnotactuated,anditcloseswhenitisactuated.
Thisisahydraulicsystemthatcanoperate multi-pleactuatorsatthesametimeregardlessoftheload.
PCPressureCompensation HydraulicsystemThisisafunctionthatcorrectstheoilpressure.
PCCSPalmcommandcontrolsystem Steering (DSeries)
PCVPre-strokeControl Valve Engine
PPCProportionalPressure Control
Thisisafunctionthatelectricallycontrolsthe engineandtransmissioninanoptimalwaywith thecontrollerinstantlyanalyzingdatafrom levers,pedals,anddials.
Thisisavalvethatadjuststhefuelintake amountatthepumpinletinordertocontrolfuel dis-chargedvolumeofsupplypump.
HydraulicsystemThisisasystemthatoperatesactuatorsinproportiontotheoilpressure.
PPMPistonPumpand Motor Hydraulicsystem (D,PC,etc) Pistontypehydraulicpumpandmotor.
PTOPowerTakeOffPowertrainsystemPowertake-offmechanism
PTPPowerTiltandpower Pitchdozer Workequipment (DSeries)
ROPSRoll-OverProtective StructureCabandcanopy
SCRSelectiveCatalyticReduction UreaSCRsystem
SI LeSystemeInternationald'Unites(Internationalunitsystem) Unit
SOL
Thisisafunctionthatperformshydrauliccontrolofthetiltandpitchofthedozerbladeofthe bull-dozer.
ROPSisaprotectivestructurethatintendedto protecttheoperatorwearingseatbeltfromsufferinginjurywhichmaybecausedifthecabis crushedwhenthemachinerollsover.(Rolloverprotectivestructure)
ThisperformanceisstandardizedasISO3471 orISO12117-2.
Thisisanexhaustgaspurifierusingureawater thatconvertsnitrogenoxides(NOx)intoharmlessnitrogenandwaterbyoxidation-reduction re-action.Itmayalsobementionedasexhaust gaspurificationcatalystorpartofthenameof relateddevices.
Abbreviationfor"InternationalSystemofUnits" Itistheuniversalunitsystemand"asingleunit forasinglequantity"isthebasicprinciple applied.
SolenoidElectricalsystemThisisanactuatorthatconsistsofasolenoid andanironcorethatisoperatedbythemagneticforcewhenthesolenoidisenergized.
Abbrevia-tionActualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
TOPSTip-OverProtective StructureCabandcanopy
Explanation
Thisisaprotectivestructurethatintendedto protecttheoperatorwearingseatbeltfromsufferinginjurywhichmaybecausedifthecabis crushedwhenthemachinetipsover.(Roll-over protectivestructureofhydraulicexcavator)
ThisperformanceisstandardizedasISO 12117.
TWV2-WayValveHydraulicsystemThisisasolenoidvalvethatswitchesover directionofflow.
VGTVariableGeometryTurbochargerEngine
VHPCVariableHorsePower Control Enginecontrol
*1:Codeforapplicablemachinemodel
D:Bulldozer
HD:Dumptruck
HM:Articulatedumptruck
PC:Hydraulicexcavator
WA:Wheelloader
Thisisaturbochargeronwhichthecross-sectionareaoftheexhaustpassageisvariable.
Thisisafunctionthatfinelycontrolsthemaximumoutputofthemachinesothathighwork efficiencyandlowfuelconsumptionrateare bothachieved.
Listofabbreviationsusedinthecircuitdiagrams
AbbreviationActualwordspelledout
A/CAirConditioner
A/DAnalogue-to-Digital
A/MAirMixDamper
ACCAccessory
ADDAdditional
AUXAuxiliary
BRBatteryRelay
CWClockwise
CCWCounterClockwise
ECUElectronicControlUnit
ECMElectronicControlModule
ENGEngine
EXGNDExternalGround
F.G.FrameGround
GNDGround
IMAInletMeteringActuator
NCNoConnection
S/T
STRGSteering
SIGSignal
SOLSolenoid
STDStandard
OPT
OPOption
PRESSPressure
SPECSpecification
SWSwitch
TEMPTemperature
T/CTorqueConverter
T/MTransmission
Someoftheattachmentsandoptionsdescribedinthisshop manualmaynotbeavailableinsomeareas.Iftheyarerequired,consultyourKomatsudistributor.
Thematerialsandspecificationsaresubjecttochangewithoutnotice.
ShopManualsareavailablefor"machinepart"and"engine part".Fortheengineunit,seetheshopmanualforthemachinewhichhasthesameenginemodel.
Actualmachinemaydifferfromtheimageswhicharecontainedinthismanual.Atypicalmodelisshownintheillustrationsofthisshopmanual.
Thisshopmanualcontainstechnicalinformationnecessaryto performservicesinworkshops.Itisdividedintothefollowing chaptersfortheeaseofuse.
00INDEXANDFOREWORD
Thissectiondescribestheindex,foreword,safety,andbasicinformation.
STRUCTUREANDFUNCTION
Thissectiondescribesthestructureandoperationofeachcomponentwithrespecttoeachsystem."STRUCTUREANDFUNCTION"ishelpfulinnotonlyunderstandingthestructureofeach componentbutperformingtroubleshooting.
Thissectiondescribesthestandardvaluesfornewmachineand failurecriteriafortestingandadjusting,andtroubleshooting.Use thestandardvaluestabletocheckthestandardvaluesfortestingandadjusting,andjudgetroublesintroubleshooting.
Thissectiondescribesthemeasuringtoolsandmeasuring methodsfortestingandadjustingaswellastheadjustingmethodofeachpart.ThestandardvaluesandrepairlimitforTESTINGANDADJUSTINGaredescribedin"STANDARDVALUE TABLE".
40TROUBLESHOOTING
Thissectiondescribestroubleshootingoffailurepartandits remedymethodontheoccurrenceofthefailure.Descriptionsof troubleshootingaresortedbyfailuremode.
50DISASSEMBLYANDASSEMBLY
Thissectiondescribesthespecialtools,workprocedures,and safetyprecautionsnecessaryforremoval,installation,disassembly,andassemblyofthecomponentsandparts.Inaddition, tighteningtorques,quantity,andweightofthecoatingmaterials, lubricants,andcoolantnecessarytotheseworksareshown.
60MAINTENANCESTANDARDS
Thissectiondescribesthemaintenancestandardvalueofeach component.Themaintenancestandardshowsthecriteriaand remediesfordisassemblyandassembly.
80THEOTHERINFORMATION
Thissectiondescribesthestructureandfunction,testingand adjusting,andtroubleshootingforalloftheothercomponentsor equipmentwhichcannotbeseparatelyclassifiedintheappendix.
90Circuitdiagrams
Thissectiondescribeshydrauliccircuitdiagramsandelectrical circuitdiagrams.
Symbols
Importantsafetyandqualityportionsaremarkedwiththefollowingsymbolssothatshopmanualisusedeffectively.
SymbolItem
4 3 2 5 6 ,
Signalword
DangerThissignalindicatesanextremelyhazardoussituationwhichwillresultin deathorseriousinjuryifitisnotavoided.
WarningThissignalindicatesapotentiallyhazardoussituationwhichwillresultin deathorseriousinjuryifitisnotavoided.
CautionThissignalindicatesapotentiallyhazardoussituationwhichwillresultin injuryorpropertydamagearoundthemachineifitisnotavoided.
Weight
Tightening torque
Thissignalindicatestheweightofpartsandcomponents,anditemswhich requiresgreatattentiontoaselectionofwiresandworkingposturefor slingingwork.
Thissignalindicatesthetighteningtorqueforportionswhichrequiresspecialcareinassemblingwork.
CoatThissignalindicatesaplacetobecoatedwithadhesive,grease,etc.in assemblingwork.
OilandcoolantThissignalindicatesaplacetosupplyoil,coolant,etc.andthequantity
DrainingThissignalindicatesaplacetodrainoil,coolant,etc.andthequantity.
SafetyThissymbolindicatestheworkswhichrequirespecialcautionforthe machinesafetywhenassembling.
Signalwordfornoticeandremarkdescribesthefollowing.
SymbolItemRemark
NOTICENoticeIftheprecautionofthissignalwordisnotobserved,themachinedamageorshorteningofservicelifemayoccur.
REMARKRemarkThissignalwordcontainsusefulinformationtoknow.
Unit
InternationalSystemofUnits(SI)isusedinthismanual.Forreference,unitsthathavebeenusedinthepastaregivenin{}.
Appropriateservicingandrepairareextremelyimportantto ensuresafeoperationofthemachine.Theshopmanuals describetheeffectiveandsafeservicingandrepairmethods recommendedbyKomatsu.Someoftheservicingandrepairmethodsrequiretheuseofspecialtoolsdesignedby Komatsuforspecialpurposes.
Thesymbolmarkisindicatedforsuchmattersthatrequirespecialprecautions.Theworkindicatedwiththiswarningmarkshouldbeperformedaccordingtothe instructionswithspecialattention.Shouldahazardoussituationoccurorbeanticipatedduringsuchwork,besureto keepsafefirstandtakeeverynecessarymeasure.
Wellorganizedworkplace
Correctworkclothes
Observanceofworkstandard
Enforcementofhandsignals
Prohibitionagainstunlicensedpersonsoperatingandhandlingthemachine
Safetycheckbeforestartingwork
Wearofdustglasses(forcleaningorgrindingwork)
Wearofweldinggogglesandprotectors(forweldingwork)
Beingingoodphysicalcondition,andgoodpreparation
Alwaysbealertandcareful.
kIfthemachineishandledincorrectly,itisdangerous. Readandunderstandwhatisdescribedintheoperationandmaintenancemanualbeforeoperation.Read andunderstandwhatisdescribedinthismanualbefore operation.
Readandunderstandthemeaningofallthesafetylabels stucktothemachinebeforeperforminganygreasingorrepairs.Forthelocationsofthesafetylabelsanddetailedexplanationofprecautions,seeOperationandMaintenance Manual.
Toolsandremovedpartsintheworkshopshouldbewellorganized.Alwayskeepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareacleanandmakesure thatthereisnodust,dirt,oil,orwateronthefloor.Smoke onlyinthedesignatedareas.Neversmokewhileworking.
Keepalltoolsingoodcondition,learnthecorrectwaytouse them,andusetheproperones.Checkthetools,machine, forklifttruck,servicecar,etc.thoroughlybeforestartingthe work.
Alwayswearsafetyshoesandhelmetwhenperformingany operation.Donotwearlooseclothes,orclotheswithbuttons missing.
Alwaysweartheprotectiveeyeglasseswhenhittingparts withahammer.
Alwaysweartheprotectiveeyeglasseswhengrindingparts withagrinder,etc.
Whenperforminganyoperationwithmultipleworkers,alwaysagreeontheoperatingprocedurebeforestarting.Be clearinverbalcommunicationandobservehandsignals. Hang"UNDERREPAIR"warningtagintheoperator'scompartmentBeforestartingwork.
Workandoperationwhichrequirelicenseorqualification shouldbeperformedbyqualifiedworkers.
Weldingrepairsshouldbeperformedbytrainedandexperiencedwelders.Whenperformingweldingwork,always wearweldinggloves,apron,weldinggoggles,capandother clothessuitedforweldingwork.
Warmupbeforestartingtheworkwithexercisewhichincreasesalertnessandtherangeofmotioninordertopreventinjury.
Avoidprolongedworkandtakearestattimestokeepupa goodcondition.Takearestatdesignatedsafearea.
Placethemachineonafirmandlevelgroundandapplythe parkingbrakeandchockthewheelsortrackstopreventthe machinefrommovingbeforeaddingoilormakinganyrepairs.
Lowertheworkequipment(blade,ripper,bucket,etc.)tothe groundbeforestartingwork.Ifthisisnotpossible,insertthe lockpinoruseblockstopreventtheworkequipmentfrom falling.Inaddition,besuretolockallthecontrolleversand hang"UNDERREPAIR"warningtagonthem.
Whenperformingthedisassemblingorassemblingwork, supportthemachinesecurelywithblocks,jacks,orstands beforestartingthework.
Removeallmudandoilfromthestepsorotherplacesfor goingupanddownonthemachine.Alwaysusethehandrails,laddersorstepswhenforgoingupanddownonthe machine.Neverjumponoroffthemachine.Whenthescaffoldisnotprovided,usestepsorstepladdertosecureyour footing.Donotusehandrails,ladders,orstepsiftheyare damagedordeformed.Repairitorreplaceitimmediately.
Forthemachinewiththebatterydisconnectswitch,check beforestartingtheworkthatthesystemoperatinglampis notlit.Then,turnthebatterydisconnectswitchtoOFF() position
REMARK
RemovethekeyafteritisturnedtoOFF()positionifthe batterydisconnectswitchisaswitchkeytype.Forthemachinewithoutthebatterydisconnectswitch,turnthestarting switchtoOFFposition,waitfortwominutesormorebefore startingthework.Disconnectthebatterycablebystarting fromthenegative(-)terminalfirst.
Forthemachinewiththequickreleasebatteryterminal(-), checkbeforestartingtheworkthatthesystemoperating lampisnotlit.Then,disconnectthequickreleasebattery terminal(-).
Forthemachinewithoutthesystemoperatinglamp,turnthe startingswitchtoOFFposition,waitfortwominutesormore beforestartingthework.Disconnectthequickreleasebatteryterminal(-).
Releasetheremainingpressurefromthecircuitbeforestartingtheworkofdisconnectingandremovingofoil,fuel,water,orairfromthecircuit.Whenremovingthecapofoilfilter, drainplug,oroilpressureplug,itshouldbedoneslowlyotherwisetheoilspills.