Komatsu Wheel Loader WA900-8R service & repair manual

Description Komatsu Wheel Loader WA900-8R service & repair manual

Komatsu Wheel Loader WA900-8R pdf workshop service & repair manual

Serial numbers:
95001 and up

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

MANUAL CONTENT:
Index and Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Dispose of Waste Materials
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
Standard Tightening Torque Table
Conversion Table
Abbreviation List

Specifications
Specification Drawing
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Boot-up System
Layout Drawing of Boot-up System
Pre-lubrication System
System Operating Lamp System
Battery Disconnect Switch
Starting Motor Disconnect Switch
Preheating System
Engine Shutdown Secondary Switch
Emergency Engine Stop Switch
External Power Supply Engine Preheater
Engine System
Layout Drawing of Engine System
Engine Control System
Engine Power Mode Selector 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
Machine Lock-out System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Work Equipment Pump Control System
Steering Pump Control System
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Transmission Control System
Transmission Gear Shift Control System
Transmission Protection Function
Tire Slip Control System
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
Semi-Auto Approach System
Semi-Auto Dump System
ECSS
Wall Digging Prevention Control System
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System
Secondary Steering System
AJSS
Steering Lock System
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Parking Brake Control System
Component Parts of Brake System
Auto-Greasing System
Layout Drawing of Auto-Greasing System
Auto-Greasing System Diagram
Specifications of Auto-Greasing System
Function of Auto-Greasing System
Auto-Greasing System
Lifting System
Power Ladder System
Undercarriage and Frame
Frame, Axle Mount and Hinge Pin
Structure of Lubrication System for Undercarriage
Service Center
Tires
Work Equipment
Structure of Work Equipment
Structure of Bucket
Structure of Lubrication System for Work Equipment
CAB Related Parts
ROPS
CAB
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Machine
Machine Posture and Procedures to Measure Performance

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjustin
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 and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Examine Low Pressure Circuit Devices
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Examine Muffler and Muffler Stack for Looseness and Damage
Examine Installation of Cylinder Head Cover and Manifolds
Examine Engine Piping for Damage and Looseness
Write Injector Compensation Value to Engine Controller
Examine and Adjust Alternator Belt
Examine and Adjust Air Conditioner Compressor Belt
Bleed Air from Engine Coolant Circuit
Power Train
Examine and Adjust Power Train Oil Pressure
Examine Modulation Clutch Output Speed Sensor
Examine Transmission Output Speed Sensor
Adjust Wheel 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 and Adjust Steering Circuit Oil Pressure
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
How to Release Nitrogen Gas When You Discard Accumulator
Examine Brake Performance
Examine Brake Pedal
Adjust Right Brake Pedal Switch
Bleed Air from Brake Circuit
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 Hydraulic System
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
Examine Hydraulic Drift of Work Equipment
Examine Work Equipment Speed
Device to Get on or Off Machine
Adjust Deceleration of Power Ladder
CAB Related Parts
Examine Work Equipment Control Lever
Examine AJSS Lever
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor
Examine and Adjust Steering Stopper Bolt
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
How to Stop Use of 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
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Examine Diodes
Pm Clinic
Pm Clinic Service
Perform Quick Pm

Troubleshooting
Precautions Before Work
Related Information for Troubleshooting
General Troubleshooting Points
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
Connectors List
Connector Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
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
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 Muffler Assembly
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Cylinder Head Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Alternator Assembly
Remove and Install Cooler Assembly
Remove and Install Radiator Core
Remove and Install Radiator Reservoir Tank 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 Brake Cooler
Remove and Install Engine Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Turbocharger Assembly
Remove and Install Upper Part of Engine
Remove and Install Top Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Drain and Add Coolant
Power Train
Remove and Install Damper Assembly
Disassemble and Assemble Damper Assembly
Remove and Install Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly
Disconnect and Connect Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly
Disconnect and Connect Torque Converter, Input Transfer and PTO Assembly
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Input Transfer and PTO Assembly
Disconnect and Connect Transmission and Transfer Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble Transfer Assembly
Remove and Install Parking Brake Assembly
Disassemble and Assemble Parking Brake Assembly
Drain and Add Transmission Oil
Remove and Install Front Axle Assembly
Remove and Install Rear Axle Assembly
Remove and Install Center Support Assembly
Disassemble and Assemble Center Support Assembly
Remove and Install Differential Assembly
Disassemble and Assemble Differential Assembly
Remove and Install Final Drive Carrier Assembly
Disassemble and Assemble Final Drive Carrier Assembly
Remove and Install Front Final Drive and Brake Assembly
Disassemble and Assemble Final Drive and Brake Assembly
Steering System
Remove and Install Steering Valve Assembly
Remove and Install Rotary Valve Assembly
Brake System
Remove and Install Right Brake Valve Assembly
Remove and Install Left Brake Valve Assembly
Remove and Install Brake Accumulator Assembly
Undercarriage and Frame
Remove and Install Front Wheel Assembly
Remove and Install Rear Wheel Assembly
Remove and Install Center Hinge Pin
Remove and Install Bumper Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install Work Equipment Pump, Pilot and Brake Charge Pump Assembly
Remove and Install Work Equipment Pump and Brake Cooling Duplex Pump Assembly
Remove and Install Secondary Steering Pump Assembly
Remove and Install Steering Pump Assembly
Remove and Install Cooling Pump and Cooling Fan Pump Assembly
Remove and Install Transmission and Torque Converter Lubrication Triplex Pump Assembly
Remove and Install Control Valve Assembly
Remove and Install Diverter Valve Assembly
Drain and Add Hydraulic Oil
Work Equipment
Remove and Install Work Equipment Assembly
Disassemble and Assemble Steering Cylinder Assembly
Disassemble and Assemble Bucket Cylinder Assembly
Disassemble and Assemble Lift Cylinder Assembly
Remove and Install Boom End (Bucket Hinge) Bushing
CAB Related Parts
Remove and Install ROPS Assembly
Remove and Install Operator CAB Assembly and Floor Frame Assembly
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat Assembly
Remove and Install Work Equipment Control Lever
How to Remove and Install Seat Belt
Remove and Install AJSS Lever Switch Assembly
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 Crankcase Pressure Sensor
Remove and Install KomVision Camera Assembly
Remove and Install KomVision Radar Assembly
Remove and Install KomVision Controller
Remove And Install KOMTRAX Plus Controller Assembly
Remove and Install Wireless LAN Unit Assembly

Maintenance Standard
Explanation of Terms for Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Center Support
Maintenance Standard for Transmission Mount
Maintenance Standard for Torque Flow Assembly
Maintenance Standard for Torque Converter
Maintenance Standard for Modulation Clutch
Maintenance Standard for Valve Assembly (For Main Relief and Torque Converter Relief)
Maintenance Standard for Torque Converter Regulator Valve
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for F, R, 1st, 2nd, 3rd Clutch ECMV
Maintenance Standard for Modulation Clutch ECMV
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 Pump
Maintenance Standard for Steering Cylinder
Brake System
Maintenance Standard for Brake
Maintenance Standard for Parking Brake
Maintenance Standard for Parking Brake Circuit Check Valve
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 Control Valve
Work Equipment
Maintenance Standard for Work Equipment Linkage
Maintenance Standard for Bucket
Maintenance Standard for Lift Cylinder
Maintenance Standard for Bucket Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount

Others
Precautions Before Work
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
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
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)
Examine Air Conditioner with Self-Diagnosis Function
Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
Examine Refrigerant (Triple) Pressure Switch
Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Air Conditioner System (A-Mode)
Connect Service Tool
KomVision System
Structure and Operation of KomVision System
Examine and Adjust KomVision System
Camera Calibration
Adjust Radar (For Machine with Radar)
Troubleshooting for KomVision System

Circuit Diagrams
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram for Work Equipment
Power Train Hydraulic Circuit Diagram
Hydraulic Circuit Diagram for Work Equipment (Combination of Forward 1st Travel, Boom RAISE and Bucket TILT Operation (1/2)
Hydraulic Circuit Diagram for Power Train (Combination of Forward 1st Travel, Boom RAISE and Bucket TILT Operation 2/2)
Hydraulic Circuit Diagram for Work Equipment (Combination of Boom LOWER, Reverse 2nd Travel, Steer Left, and Left Brake Operation 1/2)
Hydraulic Circuit Diagram for Power Train (Combination of Boom LOWER, Reverse 2nd Travel, Steer Left, and Left Brake Operation 2/2)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

Engine SAA12V140E-7 workshop service manual