Komatsu Avance Plus WA600-3LK Wheel Loader Shop Manual CEBM005502 – PDF

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Komatsu Avance Plus WA600-3LK Wheel Loader Shop Manual CEBM005502 – PDF DOWNLOAD

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Komatsu Avance Plus WA600-3LK Wheel Loader Shop Manual CEBM005502 – PDF DOWNLOAD

Language : English
Pages : 1032
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Avance Plus WA600-3LK Wheel Loader Shop Manual CEBM005502 – PDF DOWNLOAD

• SERIAL NUMBERS WA600-3LK – A53001 and UP

MAIN MENU 0
COVER 1
CONTENTS 2
FOREWORD 15
SAFETY 15
SAFETY NOTICE 15
IMPORTANT SAFETY NOTICE 15
GENERAL PRECAUTIONS 15
PREPARATIONS FOR WORK 15
PRECAUTIONS DURING WORK 15
GENERAL 17
HOW TO READ THE SHOP MANUAL 18
VOLUMES 18
DISTRIBUTION AND UPDATING 18
FILING METHOD 18
REVISED EDITION MARK 18
REVISIONS 18
SYMBOLS 18
HOISTING INSTRUCTIONS 19
HOISTING 19
WIRE ROPES 19
PUSH-PULL TYPE COUPLER 20
COATING MATERIALS 23
STANDARD TIGHTENING TORQUE 25
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 25
TIGHTENING TORQUE OF HOSE NUTS 26
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 26
TIGHTENING TORQUE FOR FLARED NUTS 26
O-RING BOSS PIPING JOINTS 27
O-RING BOSS PLUGS 27
ELECTRIC WIRE CODE 28
CLASSIFICATION BY THICKNESS 28
CLASSIFICATION BY COLOR AND CODE 28
CONVERSION TABLES 29
METHOD OF USING THE CONVERSION TABLE 29
01 GENERAL 35
DIMENSIONS 36
SPECIFICATIONS 37
WEIGHT TABLE 41
FUEL, COOLANT AND LUBRICATNTS 42
ENGINE OIL 43
NORMAL OPERATION 43
ARCTIC OPERATION 45
TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL 45
AXLE OIL 45
GREASE 46
DIESEL FUEL 46
COOLANT SPECIFICATIONS 47
GENERAL 47
WATER 47
ANTIFREEZE 47
10 STRUCTURE AND FUNCTION 49
GENERAL POWER TRAIN 53
POWER TRAIN SYSTEM 54
RADIATOR, HYDRAULIC OIL COOLER 56
TORQUE CONVERTER AND TRANSMISSION PIPING 58
HYDRAULIC CIRCUIT FOR POWER TRAIN 60
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 62
ENGINE STOPPED 62
TORQUE CONVERTER 64
REGULATOR VALVE 67
RELIEF VALVE 69
OIL COOLER 70
OIL FILTER 71
TRANSMISSION 73
TRANSMISSION CUT-A-WAY 74
FORWARD 1ST 77
FORWARD 2ND 78
FORWARD 3RD 79
FORWARD 4TH 80
REVERSE 1ST 81
CONTROL VALVE 82
SOLENOID VALVE 83
UPPER VALVE AND MAIN RELIEF VALVE 85
LOWER VALVE 86
PILOT OIL FILTER 89
PILOT REDUCING VALVE 90
PRIORITY VALVE 91
MODULATING VALVE AND QUICK RETURN VALVE 92
REDUCING VALVE 95
ACCUMULATOR VALVE 96
EMERGENCY MANUAL SPOOL 99
LUBRICATION BYPASS VALVE 100
HYDRAULIC CIRCUIT SCHEMATIC 102
FORWARD 1ST 102
TRANSFER 104
DRIVE SHAFT 105
CENTER SUPPORT 106
CENTER HINGE PIN 107
AXLE 108
FRONT AXLE 108
REAR AXLE 109
MOUNT 110
DIFFERENTIAL 112
FRONT DIFFERENTIAL 112
REAR DIFFERENTIAL 113
LIMITED SLIP DIFFERENTIAL 115
FINAL DRIVE 118
STEERING 120
PIPING 120
COLUMN 121
STEERING CONTROL VALVE 122
STEERING DEMAND VALVE 125
OVERLOAD RELIEF VALVE 126
MAIN RELIEF VALVE 128
MAIN RELIEF VALVE OPERATION 129
DEMAND VALVE OPERATION 130
WHEN STEERING SPOOL IS AT NEUTRAL 130
WHEN STEERING SPOLL IS OPERATED 131
STEERING VALVE OPERATION 133
NEUTRAL 133
TURNING RIGHT 134
TURNING LEFT 135
TWO-WAY RESTRICTION VALVE 136
STOP VALVE 137
GROUND-DRIVEN STEERING 138
DIVERTER VALVE (FOR GROUND-DRIVEN STEERING) 139
BRAKE 142
PIPING 142
BRAKE CIRCUIT DIAGRAM 144
BRAKE VALVE (RIGHT) 146
BRAKE VALVE (LEFT) 147
CHARGE VALVE 151
ACCUMULATOR (FOR BRAKE) 155
SLACK ADJUSTER 156
BRAKE 158
PARKING BRAKE 160
CALIPER 161
SPRING CYLINDER 162
SOLENOID VALVE 163
HYDRAULIC 164
WORK EQUIPMENT 164
LEVER LINKAGE 164
HYDRAULIC CIRCUIT DIAGRAM 165
HYDRAULIC PIPING 166
HYDRAULIC TANK 168
OIL FILTER BYPASS VALVE 169
BREATHER 170
PPC SYSTEM 171
ACCUMULATOR 171
PPC VALVE 172
RELIEF VALVE 176
CUT-OFF VALVE 178
MAIN CONTROL VALVE 180
2-SPOOL 180
3-SPOOL 182
MAIN RELIEF VALVE 184
SAFETY VALVE (WITH SUCTION) 185
SUCTION VALVE 186
FLOAT SELECTOR VALVE AND UNLOADER VALVE 187
BOOM AND BUCKET SPOOL HOLD POSITION 188
BOOM SPOOL AT RAISE POSITION 189
BOOM SPOOL AT LOWER POSITION 190
BOOM SPOOL AT FLOAT POSITION 191
BUCKET SPOOL AT DUMP POSITION 192
BUCKET SPOOL AT TILT POSITION 193
WORK EQUIPMENT 194
LUBRICATION 194
LINKAGE 196
BUCKET 198
BUCKET POSITIONER AND BOOM KICK OUT 199
BUCKET POSITIONER 200
BOOM KICK OUT 200
PROXIMITY SWITCH OPERATION 201
ROPS CANOPY 207
CAB 208
AIR CONDITIONER 209
PIPING 209
CONDENSER 210
COMPRESSOR 211
DRY RESERVOIR 212
ELECTRICAL CIRCUIT DIAGRAM 213
MACHINE MONITOR SYSTEM 214
MAIN MONITOR 215
MAIN MONITOR DISPLAY FUNCTION 216
MAIN MONITOR SWITCH FUNCTION 217
TROUBLE DATA DISPLAY MODE 218
MAINTENANCE MONITOR 219
MAINTENANCE MONITOR DISPLAY FUNCTION 220
JOYSTICK AND AUTOMATIC SHIFT CONTROL 221
ENGINE STARTING CIRCUIT 240
ENGINE STOP CIRCUIT 241
PRE-HEATING CIRCUIT 242
AUTOMATIC PRE-HEATING SYSTEM 242
ELECTRIC TRANSMISSION CONTROL 244
COMBINATION SWITCH 246
KICK DOWN, HOLD SWITCH 248
KICK DOWN SWITCH 248
HOLD SWITCH 248
KICK DOWN ELECTRICAL CIRCUIT 249
ELECTRIC PARKING BRAKE CONTROL 255
PARKING BRAKE SWITCH 256
PARKING BRAKE VALVE 257
PARKING SAFETY RELAY 257
NEUTRALIZER RELAY 257
EMERGENCY BRAKE SWITCH 257
ECSS SYSTEM 264
ECSS ELECTICAL DRAWING 270
20 TESTING, ADJUSTING AND TROUBLESHOOTING 271
STANDARD VALUE TABLE 273
ENGINE IN CHASSIS 273
CHASSIS 274
ELECTRICAL SYSTEM 279
SERVICE TOOLS – TESTING, ADJUSTING & TROUBLESHOOTING 292
ENGINE SPEEDS 294
TORQUE CONVERTER 295
TORQUE CONVERTER STALL SPEED 295
HYDRAULIC STALL SPEED 295
TORQUE CONVERTER STALL SPEED + HYDRAULIC STALL SPEED 296
ENGINE 297
ALTERNATOR BELT TENSION 297
BLEEDING AIR FROM FUEL CIRCUIT 297
BLOW-BY PRESSURE 297
COMPRESSION PRESSURE 297
EXHAUST GAS TEMPERATURE (EACH CYLINDER) 297
EXHAUST TEMPERATURE (OVERALL ENGINE) 297
FAN BELT 297
FUEL PUMP OUTLET PORT PRESSURE 297
HANDLING EQUIPMENT IN FUEL CIRCUIT 297
INJECTOR LIFT 297
INTAKE AIR PRESSURE (BOOST PRESSURE) 297
OIL PRESSURE 297
PRECAUTIONS WHEN OPERATING ENGINE AS AN INDIVIDUAL PART 297
PERFORMANCE TEST STANDARDS 297
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 297
RUN-IN STANDARD 297
SPEED SENSOR 297
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 297
STANDARD VALUE TABLE FOR TROUBLESHOOTING 297
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 297
TROUBLE SHOOTING OF CONTROLLER SYSTEM (EA MODE) 297
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 298
VALVE CLEARANCE 298
EXHAUST GAS COLOR 299
AIR CONDITIONER COMPRESSOR 300
BELT TENSION 300
ACCELERATOR PEDAL 301
OPERATING FORCE 301
OPERATING ANGLE 302
TORQUE CONVERTER OIL PRESSURE 303
TRANSMISSION OIL PRESSURE 303
FLUSHING THE TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 308
FAILED TRANSMISSION VALVE 310
MOVING A MACHINE 310
STEERING WHEEL 313
STEERING WHEEL PLAY 313
STEERING OIL PRESSURE 315
STEERING RELIEF VALVE PRESSURE 315
STEERING PILOT PRESSURE (STEERING CONTROL VALVE) 316
ADJUSTING THE STEERING RELIEF VALVE 317
STEERING STOP VALVE 318
BRAKE 320
BRAKE PEDAL 320
BRAKE OIL PRESSURE 322
BRAKE DISC WEAR 323
BRAKE PERFORMANCE 324
PARKING BRAKE 325
ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURES 327
PPC OIL PRESSURE 329
WORK EQUIPMENT 332
BUCKET AND BOOM CONTROL LEVERS 332
OPERATING SPEEDS 333
LIFTING TIME OF LIFT ARM 333
LOWERING THE TIME OF THE LIFT ARM 333
DUMPING TIME OF THE BUCKET 333
TILT-BACK TIME OF BUCKET 333
HYDRAULIC DRIFT 334
HYDRAULIC PRESSURE 335
BUCKET POSITIONER 340
BOOM KICK OUT 341
PROXIMITY SWITCH ACTUATION PILOT LAMP 342
MACHINE MONITOR (SPEEDOMETER MODULE) 343
SETTING THE MACHINE MODEL 344
BLEEDING AIR 345
BLEEDING THE BRAKE LINES AND WHEEL CYLINDERS 345
BLEEDING THE HYDRAULIC CYLINDERS 346
RELIEVING REMAINING HYDRAULIC PRESSURE 346
PRESSURE BETWEEN EACH HYDRAULIC CYLINDER AND CONTROL VALVE 346
PRESSURE IN THE BRAKE ACCUMULATOR CIRCUIT 346
PRESSURE IN THE PPC ACCUMULATOR CIRCUIT 346
WHEELS AND TIRES 347
ADJUSTING JOYSTICK LEVER POTENTIOMETER 348
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH 350
TROUBLESHOOTING GENERAL 351
POINTS TO REMEMBER WHEN TROUBLESHOOTING 353
SEQUENCE OF EVENTS IN TROUBLESHOOTING 355
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 356
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 356
HANDLING CONTROL BOX 361
POINTS TO REMEMBER WHEN TRUBLESHOOTING ELECTRIC CIRCUITS 361
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 362
CHECKS BEFORE TROUBLESHOOTING 364
JUDGEMENT OF POWER TRAIN 365
PRECAUTIONS WHEN TROUBLESHOOTING 366
SAFETY 366
METHODS FOR TROUBLESHOOTING 366
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 368
PREVENTING RECURRENCE OF TROUBLE 369
HYDRAULIC EQUIPMENT 369
OIL CHECKS 369
CLEANING FRAGMENTS OF DAMAGED PARTS 369
METHOD OF USING TROUBLESHOOTING CHARTS 370
CATEGORY OF TROUBLESHOOTING CODE NUMBER 370
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 370
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 372
TROUBLESHOOTING CONNECTORS 375
CONNECTOR NUMBERS, TYPES AND PINS 377
CONNECTOR ARRANGEMENT DIAGRAM 384
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 388
TROUBLESHOOTING SYSTEMS OF ECSS (D-MODE) 409
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM 410
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS 411
D-1 ECSS DOES NOT WORK 412
A ERROR CODE (d0) IS DISPLAYED 413
B NO ABNORMALITY DISPLAY IS GIVEN 414
1 DOES NOT WORK AT ALL 414
D-2 ECSS CANNOT BE CANCELED 415
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 417
ELECTRICAL DIAGRAM 419
POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING CIRCUIT DIAGRAM 419
TRANSMISSION, PARKING BRAKE CIRCUIT DIAGRAM 420
LAMP, HORN CIRCUIT DIAGRAM 421
BOOM KICK OUT, BUCKET POSITIONER CIRCUIT DIAGRAM 422
E-1 ENGINE DOES NOT START 424
A STARTING MOTOR DOES NOT TURN 424
B INSPECTION OF BATTERY, BATTERY RELAY AND STARTING SWITCH 429
E-3 ENGINE STOPS WHILE MACHINE IS TRAVELLING 430
E-4B PREHEATING FAULT 430
E-5 PARKING BRAKE DOES NOT WORK 431
A PARKING BRAKE DOES NOT WORK WHEN PARKING BRAKE SWITCH IS TURNED ON 431
B PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE D 431
E-6 PARKING BRAKE ACTIVATES WHILE MACHINE IS TRAVELLING 432
E-7 PARKING BRAKE RELEASES WHEN STARTING SWITCH TURNED TO ON 434
E-8 PARKING BRAKE WORKS NORMALLY, BUT TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE 434
E-9 TRANSMISSION DOES NOT WORK PROPERLY 436
A ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH OR NEUTRALIZER RELAY CIRCUIT 438
B NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT 442
C NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT 444
D SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT 446
1 SHORT CIRCUIT TO CHASSIS GROUND IN TRAVEL FORWARD CIRCUIT 446
2 SHORT CIRCUIT TO CHASSIS GROUND IN TRAVEL REVERSE CIRCUIT 448
E ABNORMALITY IN SHIFT SOLENOID CIRCUIT 452
F SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT 455
1 SHORT CIRCUIT TO CHASSIS GROUND IN 1ST SOLENOID CIRCUIT 455
2 SHORT CIRCUIT TO CHASSIS GROUND IN 2ND SOLENOID CIRCUIT 456
3 SHORT CIRCUIT TO GROUND CHASSIS IN 3RD SOLENOID CIRCUIT 457
4 SHORT CIRCUIT TO CHASSIS GROUND IN 4TH SOLENOID CIRCUIT 458
E-10 KICK-DOWN SWITCH DOES NOT WORK 460
E-11 KICK-DOWN SWITCH WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON 463
E-12 KICK-DOWN SWITCH WORKS IN ALL GEARS 464
E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELLING FORWARD IN 2ND GEAR 466
E-14 BOOM KICK-OUT DOES NOT WORK 468
E-15 DEFECTIVE BUCKET POSITIONER 472
E-16 POWER WINDOW DOES NOT WORK 475
A POWER WINDOW DOES NOT RISE 475
B POWER WINDOW DOES NOT LOWER 476
E-17 ABNORMALITY IN FRONT WORK LAMP 478
E-18 ABNORMALITY IN REAR WORK LAMP 478
E-19 ABNORMALITY IN TRANSMISSION CUT-OFF 478
E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 478
E-21 ABNORMALITY IN BUZZER 478
TROUBLESHOOTING ENGINE CONTROLLER SYSTEM (EA-MODE) 0
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE) 479
POWER TRAIN 481
H-1 MACHINE DOES NOT START 481
H-2 TRAVEL SPEED IS SLOW, MACHINE LACKS POWER IN ALL SPEED RANGES 482
H-3 EXCESSIVE TIME LAG WHEN STARTING ENGINE OR SHIFTING GEARS 483
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 484
STEERING SYSTEM 485
H-5 STEERING WHEEL DOES NOT TURN 485
H-6 STEERING DOES NOT TURN (MACHINE WITH JOYSTICK) 486
H-7 POOR TURNING AND STEERING RESPONSE 487
H-8 TURNING, RESPONSE OF STEERING IS POOR (MACHINE WITH JOYSTICK) 488
H-9 STEERING IS HEAVY 490
H-10 JOYSTICK IS HEAVY (MACHINE WITH JOYSTICK) 490
H-11 STEERING WHEEL SHAKES OR JERKS 491
H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK) 492
H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING 492
BRAKE SYSTEM 494
H-14 WHEEL BRAKES DO NOT WORK OR BRAKIN EFFECT IS POOR 494
H-15 WHEEL BRAKES DO NOT RELEASE OR BRAKES DRAG 496
H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR 497
H-17 PARKING BRAKE DOES NOT RELEASE OR DRAGS 498
WORK EQUIPMENT 499
H-18 NEITHER THE BOOM NOR BUCKET MOVE 499
H-19 BOTH THE BOOM AND BUCKET ARE SLOW OR LACK POWER 500
H-20 BOOM DOES NOT MOVE 501
H-21 BOOM DOES NOT MOVE (MACHINES WITH REMOTE BOOM CONTROL) 502
H-22 BOOM IS SLOW OR LACKS POWER 503
H-23 BOOM IS SLOW OR BOOM LACKS POWER (MACHINES WITH REMOTE BOOM CONTROL) 504
H-24 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT 505
H-25 BOOM DROPS MOMENTARILY WHEN CONTROL LEVE IS MOVED FROM HOLD TO RAISE 506
H-26 REMOTE BOOM CONTROL DOES NOT WORK 506
H-27 EXCESSIVE HYDRAULIC DRIFT OF BOOM 507
H-28 BUCKET DOES NOT MOVE 508
H-29 BUCKET IS SLOW OR LACKS POWER 509
H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 510
H-31 ECSS DOES NOT WORK AND THERE IS PITCHING AND BOUNCING 511
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J-MODE) 513
JUDGEMENT TABLE 515
ACTION TAKEN BY CONTROLLER 516
JOYSTICK CONTROLLER SYSTEM 516
ELECTRICAL CIRCUIT DIAGRAM 520
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED 522
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID – DETECTED WHEN SIGNAL IS OUTPUT) 523
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID – DETECTED WHEN SIGNAL IS OUTPUT) 524
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID – POWER SUPPLY SIDE) IS DISPLAYED 525
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID – POWER SUPPLY SIDE) IS DISPLAYED 526
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY) IS DISPLAYED 528
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISP 530
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS 531
J-9 ABNORMALITY IN POWER SUPPLY, POWER SUPPLY VOLTAGE 532
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT 533
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID 534
J-12 DISCONNECTION IN STEERING LEFT SOLENOID 535
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 537
MAINTENANCE MONITOR ELECTRICAL CIRCUIT DIAGRAM 538
K-1 WITH STARTING SWITCH TURNED ON, NO DISPLAYS APPEAR FOR 3 SECONDS; MAINTENANCE MONITOR DOES NO 540
A NO MAINTENANCE MONITOR LAMPS LIGHT UP 540
B SOME LAMPS DO NOT LIGHT 540
K-2 ALL MAINTENANCE MONITOR LAMPS REMAIN LIT EVEN AFTER 3 SECONDS WITH STARTING SWITCH TURNED ON 541
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS, NO MA 542
K-4 CHECK ITEM DISPLAY FLASHES WITH ENGINE STOPPED AND STARTING SWITCH TURNED TO ON 543
A ENGINE OIL LEVEL DISPLAY FLASHES 543
B ENGINE COOLANT LEVEL DISPLAY FLASHES 544
K-5 CAUTION ITEM DISPLAY FLASHES WITH ENGINE STOPPED AND STARTING SWITCH TURNED TO ON 545
A ENGINE OIL PRESSURE DISPLAY FLASHES 545
B BATTERY CHARGE LEVEL DISPLAY FLASHES 546
C BRAKE OIL PRESSURE DISPLAY FLASHES 547
D AIR CLEANER CLOGGED DISPLAY FLASHES 548
K-6 CAUTION ITEM DISPLAY FLASHES, BUT CAUTION BUZZER DOES NOT SOUND 549
K-7 NO MONITOR DISPLAY LIGHTS, BUT CAUTION BUZZER DOES SOUND 550
K-8 CAUTION ITEM DISPLAY FLASHES, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH 551
A CHECK LAMP 551
B CAUTION LAMP 551
K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES 552
A CHECK LAMP 552
B CAUTION LAMP 552
K-10 ONLY NIGHT LIGHTING OF MONITOR STAYS OFF WHEN LAMP SWITCH IS TURNED ON 553
K-11 NIGHT LIGHTING OF MONITOR LIGHTS EVEN WITH LAMP SWITCH OFF 554
K-12 SERVICE METER DOES NOT WORK 555
K-13 SERVICE METER RUNS EVEN WITH ENGINE STOPPED 555
K-14 ABNORMALITY IN GAUGES 556
A ABNORMALITY IN FUEL GAUGE 556
B ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE 557
C ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 558
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 559
ELECTRICAL CIRCUIT DIAGRAM 562
MAIN MONITOR 562
LAMP AND HORN 564
M-1 MAIN MONITOR DOES NOT WORK 565
M-2 ALL LAMPS STAY ON WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED IMMEDIATELY 566
M-3 SPEEDOMETER DOESN’T DISPLAY PROPERLY 567
M-4 ABNORMALITY IN SHIFT INDICATOR 568
A DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F 568
B DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R 568
C DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N 568
D DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROLLER IS AT 1ST 569
E DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROLLER IS AT 2ND 569
F DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROLLER IS AT 3RD 569
G DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROLLER IS AT 4TH 570
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT 571
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT 572
A LEFT-HAND TURN SIGNAL DOES NOT LIGHT 572
B RIGHT-HAND TURN SIGNAL DOES NOT LIGHT 572
M-7 ABNORMALITY IN PARKING LAMP DISPLAY 574
A PARKING LAMP DISPLAY DOES NOT LIGHT 574
B PARKING LAMP DISPLAY STAYS ON 574
M-8 ABNORMALITY IN PREHEATING DISPLAY 575
A PREHEATING DISPLAY NOT LIGHTING UP 575
B PREHEATING DISPLAY STAYS LIT 575
M-9 MONITOR NIGHT LIGHTING DOES NOT WORK 576
M-10 ABNORMALITY IN FRONT WORK LAMP 578
A NEITHER THE MONITOR DISPLAY NOR THE FRONT WORK LAMP LIGHT 578
B WORK LAMP LIGHTS BUT MONITOR DISPLAY DOES NOT LIGHT 578
C MONITOR DISPLAY LIGHTS BUT WORK LAMP DOES NOT LIGHT 579
M-11 ABNORMALITY IN REAR WORK LAMP 580
A NEITHER THE MONITOR DISPLAY NOR THE REAR WORK LAMP LIGHT 580
B WORK LAMP LIGHTS BUT MONITOR DISPLAY DOES NOT LIGHT 580
C MONITOR DISPLAY LIGHTS BUT WORK LAMP DOES NOT LIGHT 580
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 582
A TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NO SWITCHED AND DISPLAY DOES NOT CHANGE 582
B TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED 582
C CUT-OFF FUNCTION DOES NOT ACTUATE WHEN CUT-OFF SWITCH IS TURNED ON 581
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 584
A WHEN PARKING BRAKE IS APPLIED, THE BUZZER SOUNDS INTERMITTENTLY AND THE CAUTION LAMPFLASHES EV 584
B WHEN PARKING BRAKE IS APPLIED, THE BUZZER DOES NOT SOUND AND THE CAUTION LAMP DOES NOT LIGHT E 584
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP REMAIN ON CONTINUOUSLY 586
A ACTUATED CONTINUOUSLY 586
B NOT ACTUATED AT ALL 586
M-15 ABNORMALITY IN BUZZER 588
A BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH TURNED TO ON 588
B BUZZER ALWAYS SOUNDS 588
M-16 CONDITION OF MONITOR SWITCHES NOT STORED IN MEMORY 590
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 592
A FAILURE DISPLAY MODE DOES NOT WORK 592
B COUNT FOR TIME ELAPSED SINCE LAST FAILURE DISPLAY MODE DOES NOT ADVANCE 592
M-18 ANORMALITY IN GROUND-DRIVEN STEERING DISPLAY 594
A GROUND-DRIVEN STEERING DISPLAY DOES NOT FLASH 594
B GROUND-DRIVEN STEERING DISPLAY FLASHES ALL THE TIME 594
M-20 ABNORMALITY IN ECSS SYSTEM 595
A DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED 595
B MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK 595
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) 596
TROUBLESHOOTING ENGINE MECHANICAL SYSTEM (S-MODE) 0
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T-MODE) 597
METHOD OD DISPLAYING ACTION CODE AND FAILURE CODE 599
JUDGEMENT TABLE 600
TRANSMISSION CONTROLLER SYSTEM-RELATED PARTS 600
ACTION TAKEN BY CONTROLLER 602
TRANSMISSION CONTROLLER SYSTEM ELECTRICAL CIRCUIT DIAGRAM 606
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LA 608
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOI 609
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOI 610
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLEN 611
T-5 FAILURE CODE [154] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLE 612
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLEN 613
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLEN 614
T-8 FAILURE CODE [18] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DIS 616
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED 618
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED 622
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED 625
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 626
T-13 SHIFT-UP DOES NOT WORK 628
T-14 SHIFT DOWN DOES NOT WORK 628
T-15 TRANSMISSION CUT-OFF DOES NOT WORK OR STAYS WORKING 630
T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING 631
T-17 BUZZER DOES NOT WORK 632
T-18 ABNORMALITY IN NETWORK SYSTEM 633
T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY 634
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM 635
T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS 636
TROUBLESHOOTING AIR CONDITIONER (DENSO) 637
AIR CONDITIONER / HEATER (DENSO) 638
VISUAL AND AUDIBLE INSPECTION 638
TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE) 639
NORMAL CONDITIONS 639
INSUFFICIENT REFRIGERANT 639
REFRIGERANT FAILS TO CIRCULATE (SYSTEM CLOGGED) 640
MOISTURE IN SYSTEM 640
COMPRESSOR FAILURE 640
EXCESSIVE REFRIGERANT OR INSUFFICIENT CONDENSER COOLING 641
AIR IN THE SYSTEM 641
EXPANSION VALVE OPENS TOO FAR 641
TROUBLESHOOTING THE ELECTRICAL CIRCUIT 642
BLOWER TROUBLESHOOTING 642
ELECTRICAL CIRCUIT CHECKS 644
HEATER RELAY 644
BLOWER SWITCH 644
COOLER CIRCUIT TROUBLESHOOTING 646
AIR CONDITIONER SWITCH 646
MAGNETIC CLUTCH RELAY 646
CONDENSER FAN OPERATION CIRCUIT 647
ERROR MESSAGE TABLES 650
A PROBLEM – EO ERROR MESSAGE DISPLAY ON THE CONTROLLER 650
B PROBLEM – E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER 650
C FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS 651
D PROBLEM – NO HEAT 651
E PROBLEM – NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF, WHEN THE POWER IS TURNED ON 651
F PROBLEM – COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS DEFROST BUTTON IS PUSHED 652
WIRING DIAGRAM 654
WIRE CHART 655
INSPECTION AREAS 656
TROUBLESHOOTING ENGINE FAULT DIAGNOSTICS 657
ENGINE FAULT DIAGNOSTICS 658
ERROR CODE DISPLAY 658
AN ENGINE CONTROLLER DISPLAYS THE ENGINE CONDITIONS IN THE FOLLOWING TWO MODES 659
DISPLAY OF NATURE AND EXTENT OF ENGINE TROUBLE 659
DISPLAY OF ERROR CODE (METHOD FOR CONFIRMING THREE-DIGIT ERROR CODES) 659
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED 660
30 DISASSEMBLY AND ASSEMBLY 671
METHOD OF USING MANUAL 675
PRECAUTIONS DURING OPERATION 676
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 676
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 677
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 678
OTHER PRECAUTIONS 678
SPECIAL TOOL LIST 680
SKETCHES OF SPECIAL TOOLS 687
ENGINE 695
AFTERCOOLER CORE 695
ALTERNATOR 695
CYLINDER HEAD 695
ENGINE FRONT SEAL 695
ENGINE OIL COOLER 695
ENGINE REAR SEAL 695
FUEL INJECTION PUMP 695
NOZZLE HOLDER 695
STARTING MOTOR 695
THERMOSTAT 695
TURBOCHARGER 695
WATER PUMP 695
RADIATOR 696
REMOVAL 696
INSTALLATION 698
ENGINE AND TORQUE CONVERTER 699
REMOVAL 699
INSTALLATION 702
TORQUE CONVERTER 703
REMOVAL 703
INSTALLATION 704
DISASSEMBLY 705
ASSEMBLY 710
TRANSMISSION 716
REMOVAL 716
INSTALLATION 719
DISASSEMBLY 720
ASSEMBLY 735
TRANSMISSION VALVE 751
REMOVAL 751
INSTALLATION 752
TRANSFER 753
DISASSEMBLY 753
ASSEMBLY 761
CENTER SUPPORT 772
REMOVAL 772
INSTALLATION 773
DISASSEMBLY 773
ASSEMBLY 775
DRIVE SHAFT 778
DISASSEMBLY 778
ASSEMBLY 780
FRONT AXLE 783
REMOVAL 783
INSTALLATION 784
REAR AXLE 785
REMOVAL 785
INSTALLATION 789
DIFFERENTIAL 790
REMOVAL (FRONT) 790
INSTALLATION (FRONT) 792
REMOVAL (REAR) 793
INSTALLATION (REAR) 794
DIFFERENTIAL, NORMAL – STANDARD 795
DISASSEMBLY 795
FINE DISASSEMBLY OF THE PINION ASSEMBLY 797
FINE DISASSEMBLY OF THE DIFFERENTIAL GEAR CASE ASSEMBLY 798
FINE ASSEMBLY OF THE DIFFERENTIAL GEAR CASE 799
FINE ASSEMBLY OF PINION ASSEMBLY 800
ASSEMBLY 801
DIFFERENTIAL, LIMITED SLIP 807
DISASSEMBLY 807
FINE DISASSEMBLY OF THE PINION ASSEMBLY 809
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY 810
ASSEMBLY 811
FINE ASSEMBLY OF PINION ASSEMBLY 812
ASSEMBLY OF DIFFERENTIAL ASSEMBLY 813
FINAL DRIVE 821
REMOVAL & DISASSEMBLY 821
ASSEMBLY & INSTALLATION 823
STEERING 827
STEERING CONTROL VALVE 827
REMOVAL 827
INSTALLATION 828
STEERING CYLINDER 829
REMOVAL 829
INSTALLATION 830
DISASSEMBLY 831
ASSEMBLY 833
STEERING VALVE 835
REMOVAL 835
INSTALLATION 836
CUT-OFF VALVE 837
REMOVAL 837
INSTALLATION 837
STOP VALVE 838
REMOVAL 838
INSTALLATION 838
GROUND-DRIVEN STEERING 839
GROUND-DRIVEN STEERING PUMP 839
INSTALLATION 840
DIVERTER VALVE 841
REMOVAL 841
INSTALLATION 842
BRAKE 843
BRAKE VALVE 843
REMOVAL 843
INSTALLATION 843
BRAKE VALVE (RIGHT SIDE) 844
DISASSEMBLY 844
ASSEMBLY 846
BRAKE VALVE (LEFT SIDE) 848
DISASSEMBLY 848
ASSEMBLY 850
SLACK ADJUSTER 852
REMOVAL 852
INSTALLATION 852
DISASSEMBLY 853
ASSEMBLY 854
ACCUMULATOR 855
REMOVAL 856
INSTALLATION 856
BRAKE 857
REMOVAL 857
INSTALLATION 858
DISASSEMBLY (FRONT OR REAR) 859
ASSEMBLY (FRONT OR REAR) 861
PARKING BRAKE 865
SOLENOID VALVE 865
REMOVAL 865
INSTALLATION 865
PARKING BRAKE 866
REMOVAL 866
INSTALLATION 867
CALIPERS 868
DISASSEMBLY 868
ASSEMBLY 869
PAD 870
REMOVAL 870
INSTALLATION 871
HYDRAULICS 872
PUMP 872
REMOVAL 872
INSTALLATION 873
TANK 874
REMOVAL 874
INSTALLATION 875
FILTER 876
REMOVAL 876
INSTALLATION 876
PPC VALVE 877
REMOVAL 877
INSTALLATION 878
DISASSEMBLY 879
ASSEMBLY 879
MAIN CONTROL VALVE 880
REMOVAL 880
INSTALLATION 881
DISASSEMBLY 882
ASSEMBLY 886
DUMP CYLINDER 889
REMOVAL 889
INSTALLATION 890
LIFT CYLINDER 891
REMOVAL 891
INSTALLATION 892
LIFT CYLINDER AND DUMP CYLINDER 893
DISASSEMBLY 893
ASSEMBLY 895
CENTER HINGE PIN 898
REMOVAL 898
INSTALLATION 904
WORK EQUIPMENT 907
REMOVAL 907
INSTALLATION 911
BULKHEAD 913
REMOVAL 913
INSTALLATION 914
FLOOR FRAME 915
REMOVAL 915
INSTALLATION 917
CAB 918
REMOVAL 918
INSTALLATION 920
MONITOR 921
REMOVAL 921
INSTALLATION 921
AIR CONDITIONER 922
COMPRESSOR 922
REMOVAL 922
INSTALLATION 922
CONDENSER 923
REMOVAL 923
INSTALLATION 924
RECEIVER TANK 925
REMOVAL 925
INSTALLATION 927
AIR CONDITIONER UNIT 926
REMOVAL 926
INSTALLATION 927
FUEL TANK 928
REMOVAL 928
INSTALLATION 929
COUNTERWEIGHT 930
REMOVAL 930
INSTALLATION 930
FRONT TIRES 931
REMOVAL 931
INSTALLATION 931
REAR TIRES 932
REMOVAL 932
INSTALLATION 932
40 MAINTENANCE STANDARD 934
ENGINE MOUNT 936
TRANSMISSION MOUNT 937
TORQUE CONVERTER 938
REGULATOR VALVE 941
TRANSMISSION 943
CLUTCH SPRINGS 943
GEARS 945
TRANSMISSION CONTROL VALVE 947
UPPER VALVE 947
RELIEF VALVE 947
LOWER VALVE 949
SOLENOID VALVE 951
TRANSFER 953
DRIVE SHAFT 955
CENTER SUPPORT 957
CENTER HINGE PIN 959
AXLE MOUNT 961
DIFFERENTIAL 963
STANDARD 963
LIMITED SLIP 967
FINAL DRIVE 969
STEERING 971
STEERING COLUMN 971
STEERING DEMAND VALVE 973
GROUND DRIVEN STEERING PUMP 974
DIVERTER VALVE 975
STEERING CYLINDER MOUNT 976
BRAKES 977
BRAKE VALVE – LEFT 977
BRAKE VALVE – RIGHT 979
SLACK ADJUSTER 981
BRAKE 983
PARKING BRAKE 985
HYDRAULIC 986
TORQUE CONVERTER CHARGING PUMP [SAL(3)-125] AND PPC PUMP [SAL(1)-32] 986
WORK EQUIPMENT PUMPS [SAL(4)-125] (2 EA ) 987
STEERING PUMP [SAL(4)-125] AND SWITCH PUMP [SAL(4)-100] 988
PPC VALVE FOR BOOM 989
PPC VALVE FOR BUCKET 989
PPC VALVE FOR ATTACHMENT 990
CUT-OFF VALVE 991
MAIN CONTROL VALVE 993
STEERING CYLINDER 995
BUCKET CYLINDER 996
BOOM CYLINDER 997
WORK EQUIPMENT 999
LINKAGE 999
BUCKET 1001
BUCKET POSITIONER 1002
BOOM KICK OUT 1002
ROPS CANOPY 1003
90 OTHERS 1004
HYDRAULIC 1006
HYDRAULIC CIRCUIT DIAGRAM 1006
ELECTRICAL 1008
CIRCUIT DIAGRAM (SHEET 1, PART 1 OF 6) 1008
CIRCUIT DIAGRAM (SHEET 1, PART 2 OF 6) 1010
CIRCUIT DIAGRAM (SHEET 1, PART 3 OF 6) 1012
CIRCUIT DIAGRAM (SHEET 1, PART 4 OF 6) 1014
CIRCUIT DIAGRAM (SHEET 1, PART 5 OF 6) 1016
CIRCUIT DIAGRAM (SHEET 1, PART 6 OF 6) 1018
CIRCUIT DIAGRAM (SHEET 2, PART 1 OF 4) 1020
CIRCUIT DIAGRAM (SHEET 2, PART 2 OF 4) 1022
CIRCUIT DIAGRAM (SHEET 2, PART 3 OF 4) 1024
CIRCUIT DIAGRAM (SHEET 2, PART 4 OF 4) 1026
CIRCUIT DIAGRAM (SHEET 3, PART 1 OF 2) 1028
CIRCUIT DIAGRAM (SHEET 3, PART 2 OF 2) 1030

DESCRIPTION:

Komatsu Avance Plus WA600-3LK Wheel Loader Shop Manual CEBM005502 – PDF DOWNLOAD

• SERIAL NUMBERS  WA600-3LK – A53001 and UP

G.B  16/12/24