Komatsu Wheel Loader WA600-8 service & repair manual

Description Komatsu Wheel Loader WA600-8 service & repair manual

Komatsu Wheel Loader WA600-8 pdf workshop service repair manual

Serial numbers:
80001 and up
80220 and up (Stone Handling spec)

Technical documentation, specifications, testing, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Procedures for Exhaust Gas Regulations
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specifications
Abbreviation List
Specification Drawing
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Abbreviation List
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Boot-up System
Layout Drawing of Boot-up System
Layout Drawing of Boot-up System (For Emergency Engine Stop Switch Spec)
System Operating Lamp System
Battery Disconnect Switch
Preheating System
Engine Shutdown Secondary Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Engine Power Mode Selector System
Automatic Idle Stop System
RPM Set
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Cooling Fan Control System
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
Rearview Monitor System
KOMTRAX Plus System
Load Meter System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Work Equipment Pump Control System
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
Transmission Control System
Transmission Gear Shift Control System
Transmission Protection Function
Component Parts of Power Train System
Work Equipment System
Layout Drawing of Work Equipment System
Work Equipment System Diagram
Work Equipment Control System
Work Equipment Neutral Lock System
Remote Positioner System
Bucket Positioner and Boom Positioner
Auto-Digging System
ECSS
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System
AJSS
Steering Column
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Parking Brake Control System
Component Parts of Brake System
Undercarriage and Frame
Frame, Axle Mount and Center Hinge Pin
Tires
Work Equipment
Structure of Work Equipment
Structure of Bucket
Structure of Lubrication System for Work Equipment
CAB Related Parts
ROPS CAB

Standard Value Table
Abbreviation List
Standard Value Table for Engine
Standard Value Table for Engine: WA600-8
Standard Value Table for Machine
Standard Value Table for Machine: WA600-8
Machine Posture and Procedures to Measure Performance

Testing and Adjusting
Precautions Before Work
Abbreviation List
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Examine Supply Pump
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Examine KDPF, SCR and Muffler Stack for Looseness and Damage
Examine Installed Condition of Cylinder Heads and Manifolds
Examine Engine Piping for Damage and Looseness
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine SCR Related Functions
Clean DEF Tank
Bleed Air from Coolant Circuit of DEF Tank
Clean DEF Pump
Bleed Air from Engine Coolant Circuit
Power Train
Examine and Adjust Power Train Oil Pressure
Adjust Modulation Clutch Rotation Sensor
Adjust Transmission Output Shaft Speed Sensor
Flush Torque Converter and Transmission Hydraulic Circuit
Move Disabled Machine Due to Transmission Valve Failure
Examine Drive Shaft for Looseness, Backlash, and Damage
Steering System
Examine Steering Wheel (For Steering Wheel Spec)
Examine and Adjust Steering Circuit Oil Pressure
Bleed Air from Steering Cylinder Circuit
Examine and Adjust Steering Stop Valve (For Steering Wheel Spec)
Brake System
Release Remained Pressure in Brake Accumulator Circuit
Examine Wheel Brake Oil Pressure
Examine and Adjust Brake Accumulator Charge Pressure
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas
Bleed Air from Brake Circuit
Examine Brake Performance
Examine Brake Pedal
Adjust Right Brake Pedal Switch
Examine Wear of Wheel Brake Disc
Examine Parking Brake Oil Pressure
Examine Parking Brake Performance
Release Parking Brake Manually
Examine Wear Volume of Parking Brake Disc
Hydraulic System
Release Remained Pressure from Work Equipment Circuit
Examine and Adjust Work Equipment Oil Pressure
Examine and Adjust Work Equipment EPC Oil Pressure
Bleed Air from Work Equipment Circuit
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Bleed Air from Cooling Fan Circuit
Examine ECSS Accumulator Charge Pressure
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas
Work Equipment
Examine and Adjust Bucket Potentiometer Lever
Examine and Adjust Boom Potentiometer Lever
CAB Related Parts
Examine Directional Lever (For Steering Wheel Spec)
Examine Work Equipment Control Lever
Examine AJSS Lever (For AJSS Spec)
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor (AJSS Specifications)
Examine and Adjust Steering Stopper Bolt (For AJSS Spec)
Adjust Play of Operator Seat
Adjust Door Lock Link
Electrical System
Set and Adjust Each Equipment
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
Default Setting of KOMTRAX Plus Controller
Default Setting of Wireless LAN Modem
Download Data from KOMTRAX Plus Controller
Adjust After Replacement of KOMTRAX Plus Controller
Adjust After Replacement of Wireless LAN Modem
Adjust Rearview Camera Angle
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Examine Diodes
Pm Clinic
Pm Clinic Service
Perform Quick Pm

Troubleshooting
Precautions Before Work
Abbreviation List
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Abbreviation List
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Fuel Doser Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Radiator Assembly
Remove and Install Cooling Fan and Fan Motor Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
Remove and Install Power Train Oil Cooler Assembly
Remove and Install Engine Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
Remove and Install KDPF Assembly
Disassemble and Assemble KDPF Assembly
Remove and Install SCR Assembly
Remove and Install KDPF and SCR Assembly
Remove and Install KCCV Assembly
Remove and Install VGT Assembly
Remove and Install DEF Mixing Tube
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Damper Assembly
Disassemble and Assemble Damper Assembly
Remove and Install Torque Converter and Transmission Assembly
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble Transfer Assembly
Remove and Install Parking Brake Assembly
Disassemble and Assemble Parking Brake Assembly
Remove and Install Front Axle Assembly
Remove and Install Rear Axle Assembly
Remove and Install Center Support Assembly
Disassemble and Assemble Center Support Assembly
Disassemble and Assemble Differential Assembly
Disassemble and Assemble Final Drive Assembly
Remove and Install Final Drive Carrier Assembly
Disassemble and Assemble Final Drive Carrier Assembly
Remove and Install Front Final Drive and Brake Assembly
Steering System
Remove and Install Steering Valve Assembly
Brake System
Disassemble and Assemble Brake Assembly
Undercarriage and Frame
Remove and Install Center Hinge Pin
Remove and Install Counterweight Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install Work Equipment Pump Assembly
Remove and Install Power Train Pump Assembly
Remove and Install Steering Pump and Cooling Fan Pump Assembly
Remove and Install Control Valve Assembly
Work Equipment
Remove and Install Work Equipment Assembly
Disassemble and Assemble Hydraulic Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Floor Frame Assembly
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat Assembly
Remove and Install Switch Assembly of AJSS Lever
Remove and Install Work Equipment Control Lever
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Work Equipment Controller Assembly
Remove and Install Transmission Controller Assembly
Remove and Install Monitor Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove and Install SCR Temperature Sensor
Remove And Install KOMTRAX Plus Controller Assembly
Remove and Install KOMTRAX Terminal Assembly
Remove and Install Wireless LAN Unit Assembly

Maintenance Standard
Abbreviation List
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Brake and Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Transmission Mount
Maintenance Standard for Torque Converter
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for Modulation Clutch ECMV
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for Forward and Reverse Clutch ECMV and 1st, 2nd, 3rd, 4th Clutch ECMV
Maintenance Standard for Torque Converter Regulator Valve
Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve
Maintenance Standard for Transmission Lubrication Relief Valve
Maintenance Standard for Front Axle
Maintenance Standard for Rear Axle
Maintenance Standard for Front Differential
Maintenance Standard for Rear Differential
Maintenance Standard for Final Drive
Steering System
Maintenance Standard for Steering Column
Maintenance Standard for Steering Pump
Maintenance Standard for Steering Valve
Maintenance Standard for Steering Cylinder
Maintenance Standard for Diverter Valve
Maintenance Standard for Secondary Steering Pump
Brake System
Maintenance Standard for Brake Valve
Maintenance Standard for Slack Adjuster
Maintenance Standard for Brake
Maintenance Standard for Parking Brake
Maintenance Standard for Parking Brake Solenoid Valve
Maintenance Standard for Brake Cooling Pump
Undercarriage and Frame
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Work Equipment Pump
Maintenance Standard for Power Train Charge Duplex Pump
Maintenance Standard for Control Valve
Work Equipment
Maintenance Standard for Work Equipment Linkage
Maintenance Standard for Bucket
Maintenance Standard for Lift Cylinder
Maintenance Standard for Bucket Cylinder

Appendix
Precautions Before Work
Abbreviation List
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
How to Replace Desiccant

Circuit Diagrams
Abbreviation List
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (For AJSS Spec)
Hydraulic Circuit Diagram (For Steering Wheel Spec)
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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