Komatsu WA900-3E0 Install guide

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

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

Table of Contents
WA900-3E0
Table of Contents 00-2
00 Index and foreword
Table of Contents.................................................................................................................... 00- 2
Table of Contents................................................................................................................. 00- 2
Foreword................................................................................................................................. 00- 6
Before reading this manual.................................................................................................. 00- 6
01 Specification
Specification............................................................................................................................ 01- 3
Specification dimension drawing.......................................................................................... 01- 3
Specifications....................................................................................................................... 01- 4
Weight table......................................................................................................................... 01- 7
Table of fuel, coolant and lubricants.................................................................................... 01- 9
10 Structure and function
Cooling system and related devices....................................................................................... 10- 3
Cooling system .................................................................................................................... 10- 3
Hydraulic system..................................................................................................................... 10- 5
Power ladder system ........................................................................................................... 10- 5
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
20 Standard value table
Standard value table............................................................................................................... 20- 3
Standard value table for chassis.......................................................................................... 20- 3
Standard value table for electrical system ........................................................................... 20- 4
30 Testing and adjusting
Testing and adjusting.............................................................................................................. 30- 3
Inspection and adjustment of potentiometer........................................................................ 30- 3
Ladder position calibration procedure.................................................................................. 30- 4
Procedure for testing diodes................................................................................................ 30- 6
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 4
Classification and procedures of troubleshooting................................................................ 40- 4
Failure codes table............................................................................................................... 40- 5
Fuse locations...................................................................................................................... 40- 7
Troubleshooting by failure code.............................................................................................. 40-9
Failure code [D1EMKA] (Disconnection of parking brake interlock relay) ........................... 40- 9
Failure code [D1EMKB] (Ground fault of parking brake interlock relay) .............................. 40- 11
Failure code [D1EMKY] (Hot short of parking brake interlock relay) ................................... 40- 12
Failure code [D1EPKA] (Disconnection of ladder drive pump relay) ................................... 40- 13
Failure code [D1EPKB] (Ground fault of ladder drive pump relay)...................................... 40- 14
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

Table of Contents
WA900-3E0
Failure code [D1ERKB] (Ladder raise solenoid output ground fault)................................... 40- 18
Failure code [D1ERKZ] (Ladder raise solenoid output abnormality:
Open circuit, hot short circuit)................................................................................... 40- 19
Failure code [D1ESKB] (Ladder lower solenoid output ground fault) .................................. 40- 20
Failure code [D1ESKZ] (Ladder lower solenoid output abnormality:
Open circuit, hot short circuit)................................................................................... 40- 21
Failure code [DBL0KR] (Power ladder controller CAN-NET signal line open circuit) .......... 40- 22
Failure code [DBL0KT] (Non-volatile memory write error)................................................... 40- 26
Failure code [DBL1KK] (Power Low Error: Battery direct)................................................... 40- 27
Failure code [DBL2KK] (Solenoid Power Low Error)........................................................... 40- 29
Failure code [DDB6KZ] (Parking brake system abnormality) .............................................. 40- 31
Failure code [DDDGKY] (Ladder operation switch hot short circuit).................................... 40- 33
Failure code [DDDKKY] (Ladder raise operation switch hot short circuit) ........................... 40- 35
Failure code [DDDLKY] (Ladder lower operation switch hot short circuit)........................... 40- 38
Failure code [DK5VKX] (Ladder angle sensor abnormality: Out of range).......................... 40- 41
Failure code [DK5VMA] (Power ladder system abnormality)............................................... 40- 43
Failure code [DUM9KY] (Ladder indicator output hot short circuit) ..................................... 40- 46
Failure code [DUM9KZ] (Ladder indicator output abnormality: Open circuit, hot short circuit)40- 47
Failure code [DV00KY] (Ladder interlock caution output hot short circuit) .......................... 40- 48
Failure code [DV00KZ] (Ladder interlock caution output abnormality:
Open circuit, ground fault)........................................................................................ 40- 49
Failure code [DWNLKA] (Ladder cushion valve output open circuit)................................... 40- 50
Failure code [DWNLKB] (Ladder cushion valve output ground fault) .................................. 40- 51
Failure code [DWNLKY] (Ladder cushion valve output hot short circuit)............................. 40- 52
Troubleshooting of electrical system (E-mode)....................................................................... 40- 53
E-1 Power ladder does not operate..................................................................................... 40- 53
E-2 Brake oil temperature warning keeps lighting............................................................... 40- 56
E-3 Parking brake does not operate (as emergency brake)................................................ 40- 58
E-4 Parking brake is applied while machine is traveling...................................................... 40- 62
E-5 Parking brake is released as starting switch is turned to ON position. ......................... 40- 65
Troubleshooting of hydraulic and mechanical system (H-mode)............................................ 40- 67
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
Troubleshooting for machine monitor (M-mode)..................................................................... 40- 74
M-1 Rear view monitor does not operate............................................................................. 40- 74
M-2 While clearance lamp is turned on, illuminance of rear view monitor remains dark..... 40- 77
M-3 Rear view monitor does not work in reverse-interlock mode........................................ 40- 78
M-4 Illuminance of rear view monitor cannot be adjusted ................................................... 40- 80
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
90 Diagrams and drawings
Hydraulic circuit diagram ........................................................................................................ 90- 3
Symbols used in hydraulic circuit diagram........................................................................... 90- 3
Power train hydraulic circuit diagram................................................................................... 90- 7
Brake, power ladder and additional cooler hydraulic circuit diagram................................... 90- 9
Work equipment hydraulic circuit diagram........................................................................... 90- 11
Electrical circuit diagram......................................................................................................... 90- 13
Symbols used in electric circuit diagram.............................................................................. 90- 13
00-3

Table of Contents
WA900-3E000-4
Electrical circuit diagram...................................................................................................... 90- 17
Connector arrangement diagram......................................................................................... 90- 21

Table of Contents
WA900-3E0 00-5

Foreword
Before reading this manual
WA900-3E000-6
Foreword 00-6
Before reading this manual 00-6
q This shop manual describes only the different part from the standard machine (WA900-3E0: S/N 60079
and up).
q 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).

WA900-3E0
SEN0565404-00 01-1
WA900-3E0
Shop Manual
01-1
WHEEL LOADER
WA900-3E0
Machine model Serial number
WA900-3E0 60079 and up
01 Specification 01-1
01-1

Contents
WA900-3E0
Contents 01-2
01 Specification
Specification............................................................................................................................ 01- 3
Specification dimension drawing.......................................................................................... 01- 3
Specifications....................................................................................................................... 01- 4
Weight table......................................................................................................................... 01- 7
Table of fuel, coolant and lubricants.................................................................................... 01- 9
01-2

Specification
Specification dimension drawing
WA900-3E0
Specification 01-3
Specification dimension drawing 01-3
WA900-3E0 01-3
01-3

Specification
Specifications
WA900-3E0
Specifications 01-4
Machine model WA900-3E0
Serial number 60079 and up
Weight
Operating weight kg 111,200
Load on front axle kg 62,020
Load on rear axle kg 49,180
Performance
Bucket capacity (heaped) m313.0
Operating load kg 23,400
Travel speed Forward 1st km/h 7.0
Travel speed Forward 2nd km/h 12.3
Travel speed Forward 3rd km/h 28.0
Travel speed Reverse 1st km/h 7.1
Travel speed Reverse 2nd km/h 12.4
Travel speed Reverse 3rd km/h 28.3
Maximum rim pull kN {kg} 588.4 {60,000}
Gradeability degree 25
Min. turning radius
Center of outside tire mm 9,200
Outside of chassis (bucket with teeth) mm 11,000
Dimension
Overall length (bucket with teeth) mm 14,058
Overall width (chassis) mm 4,585
Bucket width (outside of cutting edge) mm 4,810
Bucket width (with tire guards) mm 5,045
Overall height (to top of ROPS cab) mm 5,275
Overall height (with bucket fully
raised) mm 9,680
Wheelbase mm 5,450
Tread mm 3,350
Min. ground clearance mm 295
Maximum bucket hinge pin height mm 6,960
Dumping clearance
(tooth tip / cutting edge end) mm 4,640/5,020
Dumping reach
(tooth tip / cutting edge end) mm 2,450/2,215
Bucket tilt-forward angle degree 47
Bucket tilt-back angle (traveling pos-
ture) degree 60
Digging depth, 10 deg. (tooth tip / cut-
ting edge end) mm 470/645
01-4

Specification
Specifications
WA900-3E0
Engine
Model Komatsu SAA12V140E-3
4-cycle, water-cooled, V type 12-cylinder, direct injection,
with twin turbochargers and aftercooler
Type
Number of cylinders – Bore x Stroke mm 12 – 140 x 165
Total displacement l{cc} 30.48 {30, 480}
Flywheel horsepower kW/rpm
{PS/rpm} 638 {820}/2,050
Maximum torque Nm/rpm
{kgm/rpm} 4,089 {417}/1,300
Rated fuel consumption rate g/kWh
{g/PSh} 200.4 {147.72}
Max. speed with no load rpm 2,200
Min. speed with no load rpm 650
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 90 A x 2
Battery 12 V, 200 Ah x 2
Power train system
Torque converter 3-element, 1-stage, 1-phase (TCA51-1A)
Transmission Planetary gear, 3-forward and 3-reverse speeds
(KTM3365)
Reduction gear unit Spiral bevel gear type
Differential Straight bevel gear type
Final reduction gear Planetary gear, single reduction, oil bath type
Wheel and axle
Drive method Front and rear wheel drive
Front axle Full floating type, fixed to frame
Rear axle Full floating type, supported by center pin
Tire 45 / 65 – 45 – 58 PR (L–5)
Wheel rim 36.00 x 45 WTB
Inflation pressure kPa {kg/cm2}667 {6.8}
Brake
Foot brake Wet, multiple disc type brakes acting on front and rear
wheels independently
Hand brake Dry disc type brake acting on drive shaft (front axle),
hydraulically released and spring applied
Steering system
Type Frame articulation steering
Structure Full hydraulic power steering
Machine model WA900-3E0
Serial number 60079 and up
01-5

Specification
Specifications
WA900-3E0
Hydraulic system
Delivery of hydraulic pump
Torque converter and transmis
sion pump l/min 432 (Gear pump SAR (4) 112 + SAR (3) 100)
Steering pump l/min 315
(Fixed displacement piston pump HPF76 + 71)
Switching pump l/min 415
(Variable displacement piston pump HPV90 + 90)
PPC pump l/min 70
(Gear pump ASR (1) 32)
Brake pump l/min 30
(Gear pump SAR (1) 14)
Work equipment pump l/min 415
(Variable displacement piston pump HPV90 + 90)
Front brake cooling pump l/min 47
(Gear pump SBL (1) 24)
Rear brake cooling pump l/min 47
(Gear pump SBR (1) 24)
Power ladder pump l/min 1.8
(0.8 to 841 U)
Control valve set pressure
Transmission valve MPa {kg/cm2}2.5 {25} (Spool type, electrically controlled)
Steering valve MPa {kg/cm2}31.4 {320} (Spool type)
PPC valve MPa {kg/cm2}3.7 {38} (2-lever type)
Work equipment valve MPa {kg/cm2}34.3 {350} (2-spool type)
Ladder valve MPa {kg/cm2}RAISE 15 {153} / LOWER 12 {122}
(Spool type, electrically controlled)
Cylinder
Steering cylinder
No. of cylinders – bore x stroke mm Double-acting piston type, 2 - 160 x 503
Lift arm cylinder
No. of cylinders - bore x stroke mm Double-acting piston type, 2 - 260 x 1,368
Bucket cylinder
No. of cylinders - bore x stroke mm Double-acting piston type, 1 - 300 x 906
Ladder cylinder
No. of cylinders - bore x stroke mm Double-acting piston type, 1 - 40 x 270
Work equipment
Type of link Single Z-bar link
Shape of bucket edge Spade nose edge with tip teeth
Machine model WA900-3E0
Serial number 60079 and up
01-6

Specification
Weight table
WA900-3E0
Weight table 01-7
Unit: kg
Machine model WA900-3E0
Serial number 60079 and up
Engine (dry weight) 3,690
Radiator (dry weight) 880
Torque converter (dry weight) 590
Transmission (dry weight) 2,300
Damper 178
Upper drive shaft 58
Center drive shaft 184
Front drive shaft 171
Rear drive shaft 184
Center support 165
Front axle 8,190
Rear axle 7,700
Front differential (excluding parking brake) 1,226
Rear differential 1,256
Planetary carrier assembly (per assembly) 238
Wheel hub (per hub) 600
Axle pivot (rear) 286
Wheel (per wheel) 874
Tire (per tire) 2,720
Steering control valve 66
Steering cylinder (per cylinder) 206
Hydraulic tank (dry weight) 824
Work equipment pump 150
Parking brake assembly 185
Torque converter charging pump and PPC pump 49
Switching pump 157
Steering pump 145
Fender and guard assembly 1,393
PPC valve 4
Work equipment control valve (per valve) 95
Hydraulic oil cooler 400
ADD cooler (TC & HYD)(dry weight) 206
Front brake cooler (dry weight) 45
Rear brake cooler (dry weight) 45
Front brake cooling pump 3
Rear brake cooling pump 3
Fan motor for ADD cooler 5
01-7

Specification
Weight table
WA900-3E0
Ladder pump motor 6
Ladder power unit (including motor and bracket) assembly 59
Ladder cylinder 5
Ladder assembly 361
Lift arm cylinder (per cylinder) 998
Bucket cylinder 1,210
Engine hood (top hood / each side hood) 88/28
Front frame 7,891
Rear frame 9,644
Bucket link (including bushing) 566
Bell crank (including bushing) 1,850
Lift arm (including bushing) 8,690
Bucket (with teeth) 12,320
Counterweight 2,200 + 2,600
Fuel tank 806
Battery (per battery) 64
Cab 447
Air conditioner unit 55
Operator's seat 50
Floor board 419
ROPS support assembly 1,387
Unit: kg
Machine model WA900-3E0
Serial number 60079 and up
01-8

Specification
Table of fuel, coolant and lubricants
WA900-3E0
Table of fuel, coolant and lubricants 01-9
01-9

Specification
Table of fuel, coolant and lubricants
WA900-3E0
Important
Fuel used must be JIS diesel fuel.
The engine of this machine employs the electronically controlled high-pressure fuel injection unit in order to
secure good fuel economy and cleaner exhaust gas. Since this unit requires high parts accuracy and lubricat-
ing ability, its durability can be seriously degraded if low-viscosity fuel with low lubricating ability is used.
Note 1: Power train oil and engine oil are not identical. Use the recommended oil for each.
Note 2: When environmental preservation is an important factor for the give operation including river work,
marine and shore work and forest work, use of bio hydraulic oil and bio grease is recommended.When
using the oil and grease, please contact your Komatsu distributor for advice.
Note 3: Axle oil AX080 is capable of preventing creaking of the differential due to slippage and creaking of the
brakes. When the name AX080 alone is specified, use Komatsu genuine AX080.
Note 4: When using the machine equipped with the auto-greasing unit at temperatures below -20 °C, use
Lithium Grease No.0.
Note 5: Hyper white greases (G0-T, G2-T) are high-performance white greases.
Use of G0-T or G2-T is recommended for the following cases.
(1) When enhanced lubricating ability is required for the grease to prevent the pins and bushings from
creaking.
(2) When preventing taints on the machine appearance by black grease.
Reservoir
Engine
oil pan
Transmis-
sion
case
Hydraulic
system Brake oil tank Axle Pins Fuel tank Cooling system Power ladder
Capacity
Speci-
fied
capacity l140 164 1,065 42
360each
for front
and rear
axles
– 1,555 337 3
Refill
capacity l130 140 725 31
360each
for front
and rear
axles
–– –2
01-10

Specification
Table of fuel, coolant and lubricants
WA900-3E0
Note 6: Super Coolant
(1) Super Coolant has important functions as a corrosion inhibitor for the cooling system in addition to the
function of preventing freezing.
It is recommended to use Super Coolant even in an area where antifreeze is not required.
Komatsu does not, in principle, recommend any other coolant than Komatsu Genuine Super Coolant
(AF-NAC). Using other brands can induce serious troubles to the cooling system including the engine.
(2) For the mixing proportion of Super Coolant and dilution water, see "Mixing proportion of water and
Super Coolant ".
When the machine is shipped, Komatsu genuine Super Coolant AF-NAC is added more than 30%
unless otherwise specified. Accordingly, you need not change its concentration as long as the
minimum temperature is above -10 °C.
If the temperature drops below -10 °C, adjust concentration of Supper Coolant referencing "Mixing
proportion of water and Super Coolant".
(3) Be sure to keep the concentration of Super Coolant above 30% to maintain its corrosion inhibition
ability.
Mixing proportion of water and Super Coolant
Features of grease (reference)
Part name High load
capacity Wear-resis tant Heat-resis- tant Water-resi stant Biodegrad- able Remarks
Hyper White wwww x Non-black high load grease
Molybdenum disulfide grease QwQQ x Molybdenum grease
Lithium grease EQ Q Q x
Biogrease EQ w Q w
Synthetic biodegradable
grease
w…Excellent Q…Satisfactory E…Average x…Poor
Min. temperature ( °C)
Above -10 -15 -20 -25 -30
Mixing quantity (l)
Quantity of Super Coolant 101.1 121.3 138.2 155.0 168.5
Quantity of water 235.9 215.7 198.8 181.9 168.5
01-11

Specification
Table of fuel, coolant and lubricants
WA900-3E001-12

WA900-3E0
SEN0565406-00 10-1
WA900-3E0
Shop Manual
10-1
WHEEL LOADER
WA900-3E0
Machine model Serial number
WA900-3E0 60079 and up
10 Structure and function 10-1
10-1