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Komatsu WA900-3E0 Shop Manual

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SEN05654-00
WHEEL LOADER
WA900
-3E0
SERIAL NUMBERS
60079
and up

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Summary of Contents for Komatsu WA900-3E0

  • Page 1 SEN05654-00 WHEEL LOADER WA900 -3E0 SERIAL NUMBERS 60079 and up...

  • Page 2: Index And Foreword

    SEN0565402-00 0 0 - 1 WA900-3E0 WHEEL LOADER Shop Manual 0 0 - 1 WA900-3E0 Machine model Serial number WA900-3E0 60079 and up 00 Index and foreword 0 0 - 1 WA900-3E0 00-1...

  • Page 3: Table Of Contents

    Failure code [D1EPKY] (Short circuit of ladder drive pump relay) ........40- 15 Failure code [D1EQKY] (Ladder operation alarm relay output hot short circuit)....40- 16 Failure code [D1EQKZ] (Ladder operation alarm relay output abnormality: Open circuit, ground fault) ..................40- 17 00-2 WA900-3E0...

  • Page 4: Table Of Contents

    Symbols used in hydraulic circuit diagram................90- Power train hydraulic circuit diagram................... 90- Brake, power ladder and additional cooler hydraulic circuit diagram........90- Work equipment hydraulic circuit diagram................90- 11 Electrical circuit diagram ......................90- 13 Symbols used in electric circuit diagram................90- 13 WA900-3E0 00-3...
  • Page 5 Table of Contents Electrical circuit diagram ...................... 90- 17 Connector arrangement diagram ..................90- 21 00-4 WA900-3E0...
  • Page 6 Table of Contents WA900-3E0 00-5...

  • Page 7: Foreword

    Before reading this manual 0 0 - 6 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).
  • Page 8 SEN0565404-00 0 1 - 1 WA900-3E0 WHEEL LOADER Shop Manual 0 1 - 1 WA900-3E0 Machine model Serial number WA900-3E0 60079 and up 01 Specification 0 1 - 1 WA900-3E0 01-1...
  • Page 9 Contents Contents 0 1 - 2 01 Specification Specification..........................01- Specification dimension drawing..................01- Specifications........................01- Weight table ......................... 01- Table of fuel, coolant and lubricants ..................01- 01-2 WA900-3E0...

  • Page 10: Specification Specification

    Specification Specification dimension drawing Specification 0 1 - 3 Specification dimension drawing 0 1 - 3 WA900-3E0 0 1 - 3 WA900-3E0 01-3...

  • Page 11: Specifications

    Specification Specifications Specifications 0 1 - 4 Machine model WA900-3E0 Serial number 60079 and up Operating weight 111,200 Load on front axle 62,020 Load on rear axle 49,180 Bucket capacity (heaped) 13.0 Operating load 23,400 Travel speed Forward 1st km/h...
  • Page 12 Specification Specifications Machine model WA900-3E0 Serial number 60079 and up Komatsu SAA12V140E-3 Model 4-cycle, water-cooled, V type 12-cylinder, direct injection, Type with twin turbochargers and aftercooler Number of cylinders – Bore x Stroke 12 – 140 x 165 l{cc} Total displacement 30.48 {30, 480}...
  • Page 13 Specification Specifications Machine model WA900-3E0 Serial number 60079 and up Torque converter and transmis l/min sion pump (Gear pump SAR (4) 112 + SAR (3) 100) l/min Steering pump (Fixed displacement piston pump HPF76 + 71) l/min Switching pump (Variable displacement piston pump HPV90 + 90)

  • Page 14: Weight Table

    Specification Weight table Weight table 0 1 - 7 Unit: kg Machine model WA900-3E0 Serial number 60079 and up Engine (dry weight) 3,690 Radiator (dry weight) Torque converter (dry weight) Transmission (dry weight) 2,300 Damper Upper drive shaft Center drive shaft...
  • Page 15 Specification Weight table Unit: kg Machine model WA900-3E0 Serial number 60079 and up Ladder pump motor Ladder power unit (including motor and bracket) assembly Ladder cylinder Ladder assembly Lift arm cylinder (per cylinder) Bucket cylinder 1,210 Engine hood (top hood / each side hood)

  • Page 16: Table Of Fuel, Coolant And Lubricants

    Specification Table of fuel, coolant and lubricants Table of fuel, coolant and lubricants 0 1 - 9 WA900-3E0 01-9...
  • Page 17 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.
  • Page 18 (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.
  • Page 19 Specification Table of fuel, coolant and lubricants 01-12 WA900-3E0...

  • Page 20: Structure And Function

    SEN0565406-00 1 0 - 1 WA900-3E0 WHEEL LOADER Shop Manual 1 0 - 1 WA900-3E0 Machine model Serial number WA900-3E0 60079 and up 10 Structure and function 1 0 - 1 WA900-3E0 10-1...
  • Page 21 Power ladder system ......................10- Electrical system ........................10- 10 Power ladder controller ......................10- 10 Rear view monitor system....................10- 19 Engine service monitor system .................... 10- 22 Parking brake circuit ......................10- 24 Sensor..........................10- 26 10-2 WA900-3E0...

  • Page 22: Cooling System And Related Devices

    4. Rear brake oil cooler 10. Front brake oil cooler outlet tube 5. Hydraulic oil cooler inlet tube 11. Rear brake oil cooler inlet tube 6. Hydraulic oil cooler outlet tube 12. Rear brake oil cooler outlet tube WA900-3E0 10-3...
  • Page 23 SF1-4 SF1-4 Fin pitch (mm) 3.0P 3.0P 3.0P Total heat dissipa- 20.17 9.76 9.76 tion area (m Cross sectional area of water flow 58.72 17.78 17.78 Valve cracking pres- sure (kPa {kg/cm Valve closing pres- sure (kPa {kg/cm 10-4 WA900-3E0...

  • Page 24: Hydraulic System

    Hydraulic system Power ladder system Hydraulic system 1 0 - 5 Power ladder system 1 0 - 5 Hydraulic circuit of ladder system 1 0 - 5 WA900-3E0 10-5...
  • Page 25 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. 10-6 WA900-3E0...
  • Page 26 1.5 L tank. Motor output 1.0 kW Motor voltage 24 VDC Rated motor current 60 A 1.8 l/min Minimum delivery Rated contactor voltage 24 VDC Contactor contact capacity 120 A Contactor coil current 2.0 A Grounding method Chassis ground WA900-3E0 10-7...
  • Page 27 Relief valve B 1 0 - 8 1. Pressure adjustment screw Specification 1 0 - 8 Set relief pressure: 12 MPa {122.4 kg/cm P: From pump A: To ladder cylinder bottom T: To tank B: To ladder cylinder head 10-8 WA900-3E0...
  • Page 28 Use flow rate adjustment dial (1) to adjust the return flow rate to the tank in the ladder RAISE operation. Use flow rate adjustment dial (2) to adjust the return flow rate to the tank in the ladder LOWER operation. WA900-3E0 10-9...

  • Page 29: Electrical System

    Electrical system Power ladder controller Electrical system 1 0 - 1 0 Power ladder controller 1 0 - 1 0 Power ladder controller electrical circuit 1 0 - 1 0 10-10 WA900-3E0...
  • Page 30 Note that the ladder angle sensor voltage of 0.694 V corresponds to the ladder angle of 25 degrees. Judgment of RAISE ladder cushion control area Judgment conditions: Based on ladder potentiometer voltage A. Out of RAISE ladder cushion control area B. Area in which previous control is maintained C. RAISE ladder cushion control area WA900-3E0 10-11...
  • Page 31 Note that the ladder angle sensor voltage of 0.25 V corresponds to the ladder angle of 9 degrees. Judgment of LOWER ladder cushion control area Judgment conditions: Based on ladder potentiometer voltage A. LOWER ladder cushion control area B. Area in which previous control is maintained C. Out of LOWER ladder cushion control area 10-12 WA900-3E0...
  • Page 32 As long as the pressure switch indicates that the parking brake is released, pressing the RAISE or LOWER switches does not move the ladder. WA900-3E0 10-13...
  • Page 33 If the voltage value of β at that time is within the range of 2.5 to 5.0 V, the detected voltage is used as the value of new and updated β. After the calibration is completed, the ladder alarm sounds intermittently (short beep sounds) to inform that new calibration has been performed. 10-14 WA900-3E0...
  • Page 34 Disconnect the interlock release connector in the cab fuse box to cut the output signal from the power ladder controller to the interlock relay. In this state, the parking brake can be released in the same ways aswhen the power ladder is not installed. Electrical circuit diagram WA900-3E0 10-15...
  • Page 35 Input signal from parking brake pressure switch Applied = 0, Released = 1 D-IN-5 and 6 (*****00*) '0' is constantly displayed since it is not used. D-IN-7 (*******0 or *******1) Input signal from parking brake switch Pressed = 0, Released = 1 10-16 WA900-3E0...
  • Page 36 1 or 0 for each digit) (in ladder RAISE operation) D-OUT-19 (***0**** or ***1****) Output signal to LOWER sole- noid OFF = 0, ON = 1 (in ladder LOWER operation) D-OUT-20–23(****0000) '0' is constantly displayed since it is not used WA900-3E0 10-17...
  • Page 37 Lo side ON/OFF input D_IN_6 - - - Lo side ON/OFF input SIG_OUT_3/PLS_OUT_3/DIN P/B SW STATUS DIN7 Hi side ON/OFF input CAN0_L CAN0_L I/O KOM_NET/c CAN0_SH CAN0_SH CAN shield SOL_COM (solenoid common SOL_COM (solenoid com- GND) mon GND) 10-18 WA900-3E0...

  • Page 38: Rear View Monitor System

    And the reverse-interlock directional selector switch allows switching between the "reverse-interlock mode" and "ongoing operation mode." Camera images are output in the NTSC format. The camera is equipped with the function for automatically adjusting the light intensity and white balance. WA900-3E0 10-19...
  • Page 39 Camera NTSC signal input AV_V_NTSC_2 ··· Camera NTSC signal input AV_V_NTSC_3 ··· Return ground of camera GND_PWR_CAM Camera NTSC ground power supply Output for controlling cam- DOS_L_CAM_2 ··· Output for controlling cam- DOS_L_CAM_3 ··· GND_SIELD_CAM Camera shield GND Camera shield ground 10-20 WA900-3E0...
  • Page 40 1 0 - 2 1 CN CAM Pin No. Specification Signal name Function Remarks Camera power supply 8 V Camera power supply input VIDEO_OUT Camera NTSC signal Image output Switching between original ··· and mirror image Camera NTSC ground Ground WA900-3E0 10-21...

  • Page 41: Engine Service Monitor System

    2. Input the ID with the < and > switches, and then press the U switch to enter the service mode. 3. Using the < and > switches, display “Real-time monitor selection” screen, and then press the U switch to enter the selection. 10-22 WA900-3E0...
  • Page 42 Each time the < switch or > switch is pressed, the screens to select the following information or function are displayed in order; the transmission controller information, engine controller information, work equip- ment controller information, 2-item display function and power ladder controller information. WA900-3E0 10-23...

  • Page 43: Parking Brake Circuit

    As a result, the parking brake solenoid circuit is kept "open" and the parking brake remains ap- plied. 10-24 WA900-3E0...
  • Page 44 This sensor is installed to the ladder. If the ladder changes its angle, the sensor detects the ladder angle via the link installed on the ladder. The angle sensor is installed to the machine along with the power ladder. WA900-3E0 10-25...

  • Page 45: Sensor

    4. Switch Function 1 0 - 2 6 This sensor is installed on the side face of the engine oil pan. If the oil level drops below the specified level, the float lowers and the switch becomes "OFF". 10-26 WA900-3E0...
  • Page 46 1 is activated since the hydraulic oil sensor is in closed condition. And since the timer relay is connected to NC termi- nals, the sensing circuit of the sub-monitor connects to GND. Therefore, alarm is not displayed. WA900-3E0 10-27...
  • Page 47 If the oil is highly heated, the thermostat circuit is closed and the relay is acti- vated. As a result, the circuits of the flasher unit and the caution lamp are formed, and the brake oil temperature caution lamp starts flashing.. 10-28 WA900-3E0...

  • Page 48: Standard Value Table

    SEN0565408-00 2 0 - 1 WA900-3E0 WHEEL LOADER Shop Manual 2 0 - 1 WA900-3E0 Machine model Serial number WA900-3E0 60079 and up 20 Standard value table 2 0 - 1 WA900-3E0 20-1...
  • Page 49 Contents Contents 2 0 - 2 20 Standard value table Standard value table ....................... 20- Standard value table for chassis..................20- Standard value table for electrical system ................20- 20-2 WA900-3E0...

  • Page 50: Standard Value Table For Chassis

    Standard value table Standard value table for chassis Standard value table 2 0 - 3 Standard value table for chassis 2 0 - 3 Machine model WA900-3E0 Cate- Standard value for new Item Measurement condition Unit Repair limit gory machine...

  • Page 51: Standard Value Table For Electrical System

    PLP0 storage 0.625 V ± 0.3 V connect T-adapter. and (A) position 3) Turn starting switch to ON position, and then perform trouble- Ladder at Between PLP0 (B) shooting. boarding 4.375 V ± 0.3 V and (A) position 20-4 WA900-3E0...

  • Page 52: Testing And Adjusting

    SEN0565410-00 3 0 - 1 WA900-3E0 WHEEL LOADER Shop Manual 3 0 - 1 WA900-3E0 Machine model Serial number WA900-3E0 60079 and up 30 Testing and adjusting 3 0 - 1 WA900-3E0 30-1...
  • Page 53 Contents Contents 3 0 - 2 30 Testing and adjusting Testing and adjusting......................30- Inspection and adjustment of potentiometer ................ 30- Ladder position calibration procedure.................. 30- Procedure for testing diodes ....................30- 30-2 WA900-3E0...

  • Page 54: Inspection And Adjustment Of Potentiometer

    Thus, you can release the parking brake. When indicator lamp lights up The potentiometer may malfunction. Disable the parking brake interlock function temporarily. For details, see "Actions to be taken when the poten- tiometer failed." WA900-3E0 30-3...

  • Page 55: Ladder Position Calibration Procedure

    30-4 WA900-3E0...
  • Page 56 Display in Item Default Contents of selection English VHMS controller VHMS With Select "With" or "Without" VHMS. Pre-lubrication controller PRELUBE Without Select "With" or "Without" prelubrication controller. Power ladder controller LADDER With Select "With" or "Without" power ladder controller. WA900-3E0 30-5...

  • Page 57: Procedure For Testing Diodes

    3) Check the quality of the diode from the indi- cated value. Indicated value does not change: the di- ode does not have continuity (defective). Indicated value changes: the diode has continuity (normal). (See a below.) 30-6 WA900-3E0...

  • Page 58: Troubleshooting

    SEN0565412-00 4 0 - 1 WA900-3E0 WHEEL LOADER Shop Manual 4 0 - 1 WA900-3E0 Machine model Serial number WA900-3E0 60079 and up 40 Troubleshooting 4 0 - 1 WA900-3E0 40-1...
  • Page 59 H-1 Power ladder does not move or its speed is low............40- 67 H-2 Fan of ADD cooler does not rotate................40- 68 Troubleshooting of maintenance monitor system (K mode) ........... 40- 69 Maintenance monitor system ....................40- 69 K-1 Hydraulic oil level gauge flashes ................... 40- 71 40-2 WA900-3E0...
  • Page 60 M-5 Optional controller error and real-time monitor sreen are not displayed on engine service monitor ..................40- 82 M-6 Engine compartment lamp does not light up ..............40- 84 M-7 Step lamp does not light up ..................40- 87 WA900-3E0 40-3...

  • Page 61: General Information On Troubleshooting

    In this case, check the symptom of the failure again. Then perform the relevant troubleshooting described in the "E mode", "H mode", "S mode", "M mode", "K mode", or "W mode" section relevant to the failure. 40-4 WA900-3E0...

  • Page 62: Failure Codes Table

    Output failure (disconnection, ground fault) of DV00KZ Electrical system ladder interlock caution DWNLKA Disconnection of ladder cushion valve Electrical system DWNLKB Ground fault of ladder cushion valve Electrical system DWNLKY Hot short of ladder cushion valve Electrical system WA900-3E0 40-5...
  • Page 63 For the procedure to check failure codes on the engine service monitor, see Structure, function and main- tenance standard, "Engine service monitor" and "Service mode function". a Note: Optional equipments are also included in the table. 40-6 WA900-3E0...

  • Page 64: Fuse Locations

    4 0 - 7 Type of power Circuit breaker Circuit breaker Destination of power supply capacity 80 A Ladder pump unit Continuous power supply 20 A Engine room lamp (Battery output) 20 A CB radio and ladder control WA900-3E0 40-7...
  • Page 65 ON position or the engine is started withe the battery disconnect switch at OFF position, current concentrates on the negative fuse of CB radio and blows the fuse off, preventing the CB radio. 40-8 WA900-3E0...

  • Page 66: Troubleshooting By Failure Code

    Between ground and each of PL12 (male) (1) and Min. 1 Mz If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) WA900-3E0 40-9...
  • Page 67 Troubleshooting by failure code Failure code [D1EMKA] (Disconnection of parking brake interlock relay) 40-10 WA900-3E0...

  • Page 68: Failure Code [D1Emkb] (Ground Fault Of Parking Brake Interlock Relay)

    Between ground and each of PL12 (male) (1) and Min. 1 Mz If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) WA900-3E0 40-11...

  • Page 69: Failure Code [D1Emky] (Hot Short Of Parking Brake Interlock Relay)

    Between ground and each of PL12 (1), (2), and (3) Min. 1 Mz If no failure is found by check on causes 1 to 3, power ladder controller may be 4 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-12 WA900-3E0...

  • Page 70: Failure Code [D1Epka] (Disconnection Of Ladder Drive Pump Relay)

    Between ground and each of PL13 (male) (1) and Min. 1 Mz If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) WA900-3E0 40-13...

  • Page 71: Failure Code [D1Epkb] (Ground Fault Of Ladder Drive Pump Relay)

    Between ground and each of PL13 (male) (1) and Min. 1 Mz If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-14 WA900-3E0...

  • Page 72: Failure Code [D1Epky] (Short Circuit Of Ladder Drive Pump Relay)

    Min. 1 Mz and (3) If no failure is found by check on causes 1 to 3, power ladder controller may be 4 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) WA900-3E0 40-15...

  • Page 73: Failure Code [D1Eqky] (Ladder Operation Alarm Relay Output Hot Short Circuit)

    Between ground and each of PL14 (male) (1), (2) Min. 1 Mz If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-16 WA900-3E0...

  • Page 74: Failure Code [D1Eqkz]

    1. Turn starting switch to OFF position. Defective power ladder controller 2. Disconnect PC0 and connect T-adapters. (when measured voltage is nor- 3. Start engine and perform troubleshooting. mal) Between PC0 (female) (7) and Voltage Min. 18 V (female) (31) WA900-3E0 40-17...

  • Page 75: Failure Code [D1Erkb] (Ladder Raise Solenoid Output Ground Fault)

    Between PLUP (male) (1) and ground Min. 1 Mz If no failure is found by check on causes 1 to 3, power ladder controller may be 4 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-18 WA900-3E0...

  • Page 76: Failure Code [D1Erkz]

    Between PLUP (male) (1) and ground Min. 1 Mz If no failure is found by check on causes 1 to 3, power ladder controller may be 4 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) WA900-3E0 40-19...

  • Page 77: Failure Code [D1Eskb] (Ladder Lower Solenoid Output Ground Fault)

    Between PLDW (male) (1) and ground Min. 1 Mz If no failure is found by check on causes 1 to 3, power ladder controller may be 4 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-20 WA900-3E0...

  • Page 78: Failure Code [D1Eskz]

    Between PLDW (male) (1) and ground Min. 1 Mz If no failure is found by check on causes 1 to 3, power ladder controller may be 4 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) WA900-3E0 40-21...

  • Page 79: Failure Code [Dbl0Kr] (Power Ladder Controller Can-Net Signal Line Open Circuit)

    Open circuit in ACC signal line 1. Turn starting switch to OFF position. 2. Disconnect AB4 and PL11. a Check circuit breaker CB2 for tripping. a Check fuse PFSE for blowout. Max. 1 z Resistance Between AB4 and PL11 (female) (5) 40-22 WA900-3E0...
  • Page 80 1. Turn starting switch to OFF position. 2. Disconnect EM5 and EM6. Defective CAN terminating resis- 120 ± 12 z Between EM5 (male) (A) and (B) tor (internal open or short circuit) Resistance 120 ± 12 z Between EM6 (male) (A) and (B) WA900-3E0 40-23...
  • Page 81 If no failure is found by check on causes 1 to 8, power ladder controller may be 9 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-24 WA900-3E0...
  • Page 82 Troubleshooting by failure code Failure code [DBL0KR] (Power ladder controller CAN-NET signal line open circuit) WA900-3E0 40-25...

  • Page 83: Failure Code [Dbl0Kt] (Non-Volatile Memory Write Error)

    Calibration must be performed again by continuing ladder LOWER operation beyond default board- ing position. Cause Procedure, measuring location, criteria and remarks Power ladder controller may be defective. 1 Defective power ladder controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-26 WA900-3E0...

  • Page 84: Failure Code [Dbl1Kk] (Power Low Error: Battery Direct)

    2. Disconnect PC0. Open circuit in wiring harness Between ground and each of PC0 (female) (1) and Min. 1 Mz (short to ground circuit) Resistance Between ground and each of PC0 (female) (2) and Min. 1 Mz (12) WA900-3E0 40-27...
  • Page 85 Troubleshooting by failure code Failure code [DBL1KK] (Power Low Error: Battery direct) 40-28 WA900-3E0...

  • Page 86: Failure Code [Dbl2Kk] (Solenoid Power Low Error)

    Between PC0 (female) (30) and each of (2) and (12) 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect PC0. (short to ground circuit) Between PC0 (female) (30) and Resistance Min. 1 Mz ground WA900-3E0 40-29...
  • Page 87 Troubleshooting by failure code Failure code [DBL2KK] (Solenoid Power Low Error) 40-30 WA900-3E0...

  • Page 88: Failure Code [Ddb6Kz] (Parking Brake System Abnormality)

    Defective parking brake pressure Max. 1 z when parking switch Between F12 (female) (1) and F12 (2) brake is applied (internal open circuit) Resistance Min. 1 Mz when parking Between F12 (female) (1) and F12 (2) brake is released WA900-3E0 40-31...
  • Page 89 Displayed released. this failure code does not ap- value "0" is displayed when pear and system is normal. Code: 40989 "D-IN-4" parking brake is applied. "1" is displayed when Code: 40989 "D-IN-4" parking brake is released. 40-32 WA900-3E0...

  • Page 90: Failure Code [Dddgky] (Ladder Operation Switch Hot Short Circuit)

    Min. 1 Mz when switch is switch(internal short circuit) (female) (1) Resistance Between PLS1 (female) (4) and PLS1 Min. 1 Mz when switch is (female) (5) Between PLS1 (female) (4) and PLS1 Min. 1 Mz when switch is (female) (6) WA900-3E0 40-33...
  • Page 91 RAISE switch is ON. Displayed this failure code does not ap- value "0" is displayed when pear and system is normal. Code: 40989 "D-IN-1" LOWER switch is OFF. "1" is displayed when Code: 40989 "D-IN-1" LOWER switch is ON. 40-34 WA900-3E0...
  • Page 92 Defective parking brake pressure Max. 1 z when parking Between F12 (female) (1) and F12 (2) switch(internal open circuit) brake is appied Resistance Min. 1 Mz when parking Between F12 (female) (1) and F12 (2) brake is released WA900-3E0 40-35...
  • Page 93 RAISE switch is ON. Displayed this failure code does not ap- "0" is displayed when value Code: 40989 "D-IN-4" pear and system is normal. parking brake is applied. "1" is displayed when Code: 40989 "D-IN-4" parking brake is released. 40-36 WA900-3E0...
  • Page 94 Troubleshooting by failure code Failure code [DDDKKY] (Ladder raise operation switch hot short circuit) WA900-3E0 40-37...

  • Page 95: Failure Code [Dddkky] (Ladder Raise Operation Switch Hot Short Circuit)

    Defective parking brake pressure Max. 1 z when parking Between F12 (female) (1) and F12 (2) switch (internal open circuit) brake is applied Resistance Min. 1 Mz when parking Between F12 (female) (1) and F12 (2) brake is released 40-38 WA900-3E0...

  • Page 96: Failure Code [Dddlky] (Ladder Lower Operation Switch Hot Short Circuit)

    LOWER switch is ON. Displayed this failure code does not ap- "0" is displayed while value Code: 40989 "D-IN-4" pear and system is normal. parking brake is applied. "1" is displayed while Code: 40989 "D-IN-4" parking brake is released. WA900-3E0 40-39...
  • Page 97 Troubleshooting by failure code Failure code [DDDLKY] (Ladder lower operation switch hot short circuit) 40-40 WA900-3E0...

  • Page 98: Failure Code [Dk5Vkx] (Ladder Angle Sensor Abnormality: Out Of Range)

    Normally 0.3 to 4.7 V defective installation) Voltage 0.625 ± 0.3 V when ladder Between PLP0 (B) and (A) is in storage position 4.375 ± 0.3 V when ladder Between PLP0 (B) and (A) is in boarding position WA900-3E0 40-41...
  • Page 99 0.625 ± 0.3 V when lad- Code: 40404 "LADDER ANGLE" this failure code does not ap- Voltage der is in storage position pear and system is normal. 4.375 ± 0.3 V when lad- Code: 40404 "LADDER ANGLE" der is in boarding position 40-42 WA900-3E0...

  • Page 100: Failure Code [Dk5Vma] (Power Ladder System Abnormality)

    4.375 ± 0.3 V when ladder Between PC0 (33) and (32) is in boarding position Directly check circuit breaker CB1. (If circuit breaker is tripped, circuit probably 3 Defective circuit breaker has ground fault.) WA900-3E0 40-43...
  • Page 101 Min. 1 Mz Ground fault in wiring harness Between PC0 (female) (33) and ground Min. 1 Mz (short to ground circuit) Resistance Between PLP0 (female) (C) and ground Min. 1 Mz Between PLP0 (female) (B) and ground Min. 1 Mz 40-44 WA900-3E0...
  • Page 102 Troubleshooting by failure code Failure code [DK5VMA] (Power ladder system abnormality) WA900-3E0 40-45...

  • Page 103: Failure Code [Dum9Ky] (Ladder Indicator Output Hot Short Circuit)

    Between PIN2 (female) (+) and PIN1 (male) (-) No continuity If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-46 WA900-3E0...

  • Page 104: Failure Code [Dum9Kz] (Ladder Indicator Output Abnormality: Open Circuit, Hot Short Circuit)40

    3. Start engine and perform troubleshooting. (when measured voltage is nor- a Store ladder in position in order not to allow ladder indicator to light up. mal) Voltage Between PC0 (female) (17) and (female) (31) Min. 18 V WA900-3E0 40-47...

  • Page 105: Failure Code [Dv00Ky] (Ladder Interlock Caution Output Hot Short Circuit)

    If buzzer does not sound, it is defective. If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-48 WA900-3E0...

  • Page 106: Failure Code [Dv00Kz]

    3. Start engine and perform troubleshooting. (when measured voltage is nor- a Store ladder in position in order not to allow parking brake interlock caution mal) buzzer to sound. Voltage Between PC0 (female) (27) and (female) (31) Min. 18 V WA900-3E0 40-49...

  • Page 107: Failure Code [Dwnlka] (Ladder Cushion Valve Output Open Circuit)

    Between PLCU (male) (1) and ground Min. 1 Mz If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-50 WA900-3E0...

  • Page 108: Failure Code [Dwnlkb] (Ladder Cushion Valve Output Ground Fault)

    Between PLCU (male) (1) and ground Min. 1 Mz If no failure is found by check on causes 1 and 2, power ladder controller may 3 Defective power ladder controller be defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) WA900-3E0 40-51...

  • Page 109: Failure Code [Dwnlky] (Ladder Cushion Valve Output Hot Short Circuit)

    Between PLCU (male) (1) and ground Min. 1 Mz If no failure is found by check on causes 1 to 3, power ladder controller may be 4 Defective power ladder controller defective. (Since this is an internal defect, troubleshooting cannot be per- formed.) 40-52 WA900-3E0...

  • Page 110: Troubleshooting Of Electrical System (E-Mode)

    Between PL11 (1) and PLS1 (6) (wire breakage or defective con- tact of connector) Max. 1 z Resistance Between PL11 (1) and PLS2 (1) Max. 1 z Between PL11 (1) and PLS2 (6) Max. 1 z Between PL11 (2) and ground WA900-3E0 40-53...
  • Page 111 RAISE switch is ON Displayed "0" is displayed this failure code does not ap- value Code: 40989 "D-IN-1" when LOWER switch is pear and system is normal. "1" is displayed Code: 40989 "D-IN-1" when LOWER switch is 40-54 WA900-3E0...
  • Page 112 Troubleshooting of electrical system (E-mode), E-1 Power ladder does not operate WA900-3E0 40-55...

  • Page 113: Brake Oil Temperature Warning Keeps Lighting

    Hot short circuit in wiring harness Between INJ (female) (1) and (2) Max. 1 V (short to 24 V power supply line) Resistance Between FL (female) (4) and (1) Max. 1 V Between FNR (female) (1) and (2) Max. 1 V 40-56 WA900-3E0...
  • Page 114 Troubleshooting of electrical system (E-mode), E-2 Brake oil temperature warning keeps lighting WA900-3E0 40-57...

  • Page 115: Parking Brake Does Not Operate (As Emergency Brake)

    Hot short circuit in wiring harness 3. Start engine to charge accumulator, and then perform troubleshooting. (short to power supply circuit) Between ground and wiring harness connecting Voltage Max. 1 V PL01 (female) (C), FL1 (17) and F11 (1) 40-58 WA900-3E0...
  • Page 116 Troubleshooting of electrical system (E-mode), E-3 Parking brake does not operate (as emergency brake) Related electrical circuit diagram 4 0 - 5 9 WA900-3E0 40-59...
  • Page 117 Resistance Between CBL1 (3) and (4) Min. 1 Mz 1. Turn starting switch to OFF position. 2. Disconnect F11. 3 Defective parking brake (solenoid) 3. Start engine and perform troubleshooting. If parking brake is not applied, parking brake (solenoid) is defective. 40-60 WA900-3E0...
  • Page 118 Troubleshooting of electrical system (E-mode), E-3 Parking brake does not operate (as emergency brake) Related electrical circuit diagram 4 0 - 6 1 WA900-3E0 40-61...

  • Page 119: Parking Brake Is Applied While Machine Is Traveling

    If failure symptom disappears, emergency brake switch is defective. 1. Turn starting switch to OFF position. 2. Disconnect F11 and insert T-adapter. 5 Defective parking brake (solenoid) 3. Start engine and perform troubleshooting. Voltage Between F11 (1) and (2) 20 to 30 V 40-62 WA900-3E0...
  • Page 120 Between PL01 (female) (C) and PL12 (female) (3) Max. 1 z Between PL12 (female) (6) and L01 (male) (C) Max. 1 z Between PL01 (female) (A) and L01 (male) (A) Max. 1 z Between PL01 (female) (B) and L01 (male) (B) WA900-3E0 40-63...
  • Page 121 Troubleshooting of electrical system (E-mode), E-4 Parking brake is applied while machine is traveling. Related circuit diagram 4 0 - 6 4 40-64 WA900-3E0...

  • Page 122: Parking Brake Is Released As Starting Switch Is Turned To On Position

    Hot short circuit in wiring harness 3. Start engine to charge accumulator, and then perform troubleshooting. (short to power supply circuit) Between ground and wiring harness connecting Voltage Max. 1 V of PL01 (female) (C), FL1 (17) and F11 (1) WA900-3E0 40-65...
  • Page 123 Troubleshooting of electrical system (E-mode), E-5 Parking brake is released as starting switch is turned to ON position. Related electrical circuit diagram 4 0 - 6 6 40-66 WA900-3E0...

  • Page 124: Troubleshooting Of Hydraulic And Mechanical System (H-Mode)

    4 Ladder rises and lowers but its speed is high and shocks are made. Failure symptom changes when RAISE speed control valve is opened or closed. Failure symptom changes when LOWER speed control valve is opened or closed. 7 Pump pressure is low. 8 Hydraulic drift of ladder is large WA900-3E0 40-67...

  • Page 125: Fan Of Add Cooler Does Not Rotate

    0 When engine speed is increased, fan does not rotate. 1 When engine speed is increased, fan rotates. 2 When hydraulic oil temperature is normal, fan does not rotate. 3 When hydraulic oil temperature is normal, fan rotates. 40-68 WA900-3E0...

  • Page 126: Troubleshooting Of Maintenance Monitor System (K Mode)

    Troubleshooting of maintenance monitor system (K mode) 4 0 - 6 9 Maintenance monitor system 4 0 - 6 9 Maintenance monitor system 4 0 - 6 9 a The main monitor is the same as the machine monitor. WA900-3E0 40-69...
  • Page 127 Troubleshooting of maintenance monitor system (K mode) Maintenance monitor system 40-70 WA900-3E0...

  • Page 128: Hydraulic Oil Level Gauge Flashes

    Between RD1 (female) (6) and DA1 (female) (1) tact of connector) Max. 1 z Between T4 and ground Max. 1 z Between T2 and ground Max. 1 z Between DA1 (female) (2) and ground Max. 1 z Between L18 (female) (9) and T1 WA900-3E0 40-71...
  • Page 129 Between T4 and T1 hydraulic oil level: Max. Resistance When hydraulic oil level is low: Min. 1 Mz a When 10 sec- Between T4 and T1 onds elapsed after lowering of hy- draulic oil level 40-72 WA900-3E0...
  • Page 130 Troubleshooting of maintenance monitor system (K mode) K-1 Hydraulic oil level gauge flashes WA900-3E0 40-73...

  • Page 131: Troubleshooting For Machine Monitor (M-Mode)

    Between CA7 (female) (12) and ground Min. 1 Mz 1. Turn starting switch to OFF position. 2. Disconnect CA8 and CAM. Between CA8 (female) (1) and ground Min. 1 Mz Resistance Between CA8 (female) (2) and ground Min. 1 Mz 40-74 WA900-3E0...
  • Page 132 (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by check on causes 1 to 7, rear view camera may be defec- 8 Defective rear view camera tive. (Since this is an internal defect, troubleshooting cannot be performed.) WA900-3E0 40-75...
  • Page 133 Troubleshooting for machine monitor (M-mode) M-1 Rear view monitor does not operate 40-76 WA900-3E0...

  • Page 134: While Clearance Lamp Is Turned On, Illuminance Of Rear View Monitor Remains Dark

    Open circuit in wiring harness 2. Disconnect CA7 and FL1. (wire breakage or defective con- 3. Turn starting switch to ON position and perform troubleshooting. tact of connector) Max. 1 z Resistance Between CA7 (female) (8) and FL1 (female) (5) WA900-3E0 40-77...

  • Page 135: Rear View Monitor Does Not Work In Reverse-Interlock Mode

    4 Defective diode Between PD02 (male) (3) (+) and PD02 (male) Continuity (2) (-) Continuity Between PD02 (male) (2) (+) and PD02 (male) No continuity (1) (-) Between PD02 (male) (2) (+) and PD02 (male) No continuity (1) (-) 40-78 WA900-3E0...
  • Page 136 Troubleshooting for machine monitor (M-mode) M-3 Rear view monitor does not work in reverse-interlock mode WA900-3E0 40-79...

  • Page 137: Illuminance Of Rear View Monitor Cannot Be Adjusted

    Defective reverse-Interlock switch decrease adjust- (Internal open circuit) ment Resistance MAX. 1 z during illuminance Between CA6 (female) (5) and (4) increase adjust- ment MIN. 1 Mz dur- ing illuminance Between CA6 (female) (5) and (4) decrease adjust- ment 40-80 WA900-3E0...
  • Page 138 Troubleshooting for machine monitor (M-mode) M-4 Illuminance of rear view monitor cannot be adjusted WA900-3E0 40-81...

  • Page 139: Optional Controller Error And Real-Time Monitor Sreen Are Not Displayed On Engine Service Monitor

    If it is not configured, change setting of option and keep starting switch at OFF position for 15 sec- onds, then check again. 3: If no failure is found by check in above steps 1 and 2, engine service monitor may be defective. 40-82 WA900-3E0...
  • Page 140 Troubleshooting for machine monitor (M-mode) M-5 Optional controller error and real-time monitor sreen are not displayed on engine service monitor WA900-3E0 40-83...

  • Page 141: Engine Compartment Lamp Does Not Light Up

    2) Disconnect AB6, AR2, AR3, AR1, AR4, ABER, and ABEL. Ground fault in wiring harness Between ground and each of AR3 (female) (A), Min. 1 Mz (short to ground circuit) (B), (C) Resistance Between AR2 (female) (A) and ground Min. 1 Mz 40-84 WA900-3E0...
  • Page 142 1 V. Resistance Between AR3 (male) (B) and (C) Min. 1 Mz Between AR3 (male) (A) and ground Min. 1 Mz Between AR3 (male) (B) and ground Min. 1 Mz Between AR3 (male) (C) and ground Min. 1 Mz WA900-3E0 40-85...
  • Page 143 Troubleshooting for machine monitor (M-mode) M-6 Engine compartment lamp does not light up 40-86 WA900-3E0...

  • Page 144: Step Lamp Does Not Light Up

    1 V. Resistance Between PSS (male) (B) and (C) Min. 1 Mz Between PSS (male) (A) and ground Min. 1 Mz Between PSS (male) (B) and ground Min. 1 Mz Between PSS (male) (C) and ground Min. 1 Mz WA900-3E0 40-87...
  • Page 145 Troubleshooting for machine monitor (M-mode) M-7 Step lamp does not light up 40-88 WA900-3E0...

  • Page 146: Diagrams And Drawings

    SEN0565433-00 9 0 - 1 WA900-3E0 WHEEL LOADER Shop Manual 9 0 - 1 WA900-3E0 Machine model Serial number WA900-3E0 60079 and up 90 Diagrams and drawings 9 0 - 1 WA900-3E0 90-1...
  • Page 147 Brake, power ladder and additional cooler hydraulic circuit diagram........90- Work equipment hydraulic circuit diagram ................90- 11 Electrical circuit diagram ......................90- 13 Symbols used in electric circuit diagram................90- 13 Electrical circuit diagram ...................... 90- 17 Connector arrangement diagram ..................90- 21 90-2 WA900-3E0...

  • Page 148: Hydraulic Circuit Diagram

    Hydraulic circuit diagram Symbols used in hydraulic circuit diagram Hydraulic circuit diagram 9 0 - 3 Symbols used in hydraulic circuit diagram 9 0 - 3 (Rev. 2010/03) WA900-3E0 90-3...
  • Page 149 Hydraulic circuit diagram Symbols used in hydraulic circuit diagram 90-4 WA900-3E0...
  • Page 150 Hydraulic circuit diagram Symbols used in hydraulic circuit diagram WA900-3E0 90-5...
  • Page 151 Hydraulic circuit diagram Symbols used in hydraulic circuit diagram 90-6 WA900-3E0...

  • Page 152: Power Train Hydraulic Circuit Diagram

    Power train hydraulic circuit diagram Power train hydraulic circuit diagram WA900-3E0 WA900-3E0 WA900-3E0 90-7...

  • Page 153: Brake, Power Ladder And Additional Cooler Hydraulic Circuit Diagram

    Brake, power ladder and additional cooler Hydraulic circuit diagram Brake, power ladder and additional cooler Hydraulic circuit diagram WA900-3E0 WA900-3E0 WA900-3E0 90-9...

  • Page 154: Work Equipment Hydraulic Circuit Diagram

    Work equipment hydraulic circuit diagram Work equipment hydraulic circuit diagram WA900-3E0 WA900-3E0 WA900-3E0 90-11...

  • Page 155: Electrical Circuit Diagram

    Electrical circuit diagram Symbols used in electric circuit diagram Electrical circuit diagram 9 0 - 1 3 Symbols used in electric circuit diagram 9 0 - 1 3 (Rev. 2010/03) WA900-3E0 90-13...

  • Page 156: Electrical Circuit Diagram

    Electrical circuit diagram Symbols used in electric circuit diagram 90-14 WA900-3E0...
  • Page 157 Electrical circuit diagram Symbols used in electric circuit diagram WA900-3E0 90-15...
  • Page 158 Electrical circuit diagram Symbols used in electric circuit diagram 90-16 WA900-3E0...
  • Page 159 Electrical circuit diagram (1/2) Electrical circuit diagram (1/2) WA900-3E0 WA900-3E0 WA900-3E0 90-17...
  • Page 160 Electrical circuit diagram (2/2) Electrical circuit diagram (2/2) WA900-3E0 WA900-3E0 WA900-3E0 90-19...

  • Page 161: Connector Arrangement Diagram

    AQ-9 STEP LAMP BN-4 Terminal BATTERY RELAY RH. AS-4 Terminal FUSE 350A Terminal FUSE 350A EM41 Terminal E.ENG.STOP SW AP-6 EM42 Terminal E.ENG.STOP SW AP-9 EM51 Terminal E.ENG.STOP SW AS-3 EM52 Terminal E.ENG.STOP SW AS-3 DT2A INTERDIATE CONNECTOR WA900-3E0 90-21...
  • Page 162 LADDER RAISE SOL. AR-8 PP01 Terminal BATTERY RELAY RH. AS-3 PP02 Terminal CURCUIT BRAKER 80A AR-4 PP03 Terminal CURCUIT BRAKER 80A AR-4 PP04 Terminal LADDER PUMP UNIT AP-6 PSL1 INTERDIATE CONNECTOR BN-7 STEP LAMP SW AP-9 INTERDIATE CONNECTOR 90-22 WA900-3E0...
  • Page 163 Component name gram pins INTERDIATE CONNECTOR DTHD INTERDIATE CONNECTOR DTHD INTERDIATE CONNECTOR INTERDIATE CONNECTOR INTERDIATE CONNECTOR STARTER SW BG-2 TURBO TIMER BF-9 INTERDIATE CONNECTOR BG-2 DIODE BD-5 FUSE BOX 1 BE-5 INTERDIATE CONNECTOR BD-5 INTERDIATE CONNECTOR BP-7 WA900-3E0 90-23...
  • Page 164 Electrical circuit diagram Connector arrangement diagram 90-24 WA900-3E0...
  • Page 165 Connector arrangenment diagram (1/2) Connector arrangement diagram (1/2) WA900-3E0 WA900-3E0 WA900-3E0 90-25...
  • Page 166 Connector arrangement diagram (2/2) Connector arrangemnt diagram (2/2) WA900-3E0 WA900-3E0 WA900-3E0 90-27...
  • Page 167 Power ladder system 10-5 40-29 Power train hydraulic circuit diagram 90-7 Failure code [DDB6KZ] (Parking brake system Procedure for testing diodes 30-6 abnormality) 40-31 Failure code [DDDGKY] (Ladder operation switch hot short circuit) 40-33 Rear view monitor system 10-19 WA900-3E0...
  • Page 168 Standard value table for chassis 20-3 Standard value table for electrical system 20-4 Symbols used in electric circuit diagram 90-13 Symbols used in hydraulic circuit diagram 90-3 Table of fuel, coolant and lubricants 01-9 Weight table 01-7 Work equipment hydraulic circuit diagram 90-11 WA900-3E0...
  • Page 170 WHEEL LOADER WA900-3E0 Form No. SEN05654-00 ©2011 KOMATSU All Rights Reserved 06-11 Printed in Japan...

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