Komatsu Avance WA800-3LC Wheel Loader Shop Manual CEBM003803 – PDF

Description

Komatsu Avance WA800-3LC Wheel Loader Shop Manual CEBM003803 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Avance WA800-3LC Wheel Loader Shop Manual CEBM003803 – PDF DOWNLOAD

Language : English
Pages :931
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Avance WA800-3LC Wheel Loader Shop Manual CEBM003803 – PDF DOWNLOAD

• SERIAL NUMBERS WA800-3LC A50001 and UP

MAIN MENU 0
COVER PAGE 1
CONTENTS 2
00 FOREWORD 14
SAFETY 14
SAFETY NOTICE 14
IMPORTANT SAFETY NOTICE 14
GENERAL PRECAUTIONS 14
PREPARATIONS FOR WORK 14
PRECAUTIONS DURING WORK 14
GENERAL 16
HOW TO READ THE SHOP MANUAL 17
VOLUMES 17
DISTRIBUTION AND UPDATING 17
FILING METHOD 17
REVISED EDITION MARK 17
REVISIONS 17
SYMBOLS 17
HOISTING INSTRUCTIONS 18
HOISTING 18
WIRE ROPES 18
COATING MATERIALS 19
STANDARD TIGHTENING TORQUE 21
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 21
TIGHTENING TORQUE OF HOSE NUTS 22
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 22
TIGHTENING TORQUE FOR FLARED NUTS 22
ELECTRIC WIRE CODE 23
CLASSIFICATION BY THICKNESS 23
CLASSIFICATION BY COLOR AND CODE 23
CONVERSION TABLES 24
METHOD OF USING THE CONVERSION TABLE 24
01 GENERAL 30
SPECIFICATION DRAWING 31
SPECIFICATIONS 32
WEIGHT TABLE 35
FUEL, COOLANT AND LUBRICANTS 36
ENGINE OIL SPECIFICATIONS 37
NORMAL OPERATION 37
ARCTIC OPERATION 37
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM 38
FINAL DRIVE OIL SPECIFICATIONS 38
DRIVE AXLE OIL SPECIFICATIONS 38
DIESEL FUEL SPECIFICATIONS 38
COOLANT SPECIFICATIONS 39
SUPPLEMENTAL COOLANT ADDITIVES 41
COOLING SYSTEM TEST KIT 45
10 STRUCTURE AND FUNCTION 46
POWER TRAIN 51
OUTLINE 51
POWER TRAIN SYSTEM 52
ENGINE CONTROL 53
OUTLINE 53
RADIATOR AND HYDRAULIC OIL COOLER 54
DAMPER 55
FUNCTION 55
OPERATION 55
TORQUE CONVERTER AND TRANSMISSION PIPING 56
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 57
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 58
TORQUE CONVERTER 59
TORQUE CONVERTER RELIEF VALVE 62
OUTLINE 62
FUNCTION 62
REGULATOR VALVE 63
OPERATION 63
TRANSMISSION 64
CLUTCH 67
OUTLINE 67
OPERATION 67
FORWARD 1st 68
FORWARD 2ND 69
FORWARD 3RD 70
REVERSE 1ST 71
TRANSFER 72
OUTLINE 72
TRANSMISSION PATH 72
CONTROL VALVE 73
SOLENOID VALVE 74
LOWER VALVE 76
UPPER VALVE 77
PILOT OIL FILTER 78
MAIN RELIEF VALVE 79
PILOT REDUCING VALVE 80
PRIORITY VALVE 81
MODULATING VALVE AND QUICK RETURN VALVE 82
REDUCING VALVE 84
EMERGENCY MANUAL SPOOL 85
LUBRICATION VALVE 86
HYDRAULIC CIRCUIT SCHEMATICS 87
FORWARD 1st 87
OPERATION 88
TORQUE CONVERTER OIL COOLER 89
OUTLINE 89
DRIVE SHAFT 90
OUTLINE 90
CENTER SUPPORT 91
FUNCTION 91
AXLE 92
FRONT AXLE 92
FRONT DIFFERENTIAL 93
REAR AXLE 94
REAR DIFFERENTIAL 95
OUTLINE 96
FINAL DRIVE 97
OUTLINE 97
OPERATION 97
AXLE MOUNT 98
FRONT AXLE 99
REAR AXLE 99
CENTER HINGE PIN 100
OUTLINE 100
TIRE AND WHEEL 101
OUTLINE 101
STEERING 102
PIPING 102
STEERING COLUMN 103
STEERING PUMP 105
OUTLINE 105
SWITCH PUMP 107
OUTLINE 107
STEERING DEMAND VALVE 109
OPERATION OF DEMAND VALVE 110
OVERLOAD RELIEF VALVE 116
MAIN RELIEF VALVE 118
ORBIT-ROLL VALVE 120
OUTLINE 121
STRUCTURE 121
OPERATION 122
TWO-WAY RESTRICTOR VALVE 123
FUNCTION 123
OPERATION 123
DIVERTER VALVE 124
FUNCTION 124
GROUND DRIVEN STEERING 125
RELIEF VALVE 125
FUNCTION 125
OPERATION 125
HYDRAULIC CIRCUIT SCHEMATICS 126
PUMP, ENGINE WORKING NORMALLY 126
FAILURE IN PUMP OR ENGINE WHEN MACHINE IS TRAVELING 127
BRAKE 128
PIPING 128
BRAKE CIRCUIT DIAGRAM 129
BRAKE VALVE 131
OUTLINE 131
OPERATION 132
CHARGE VALVE 135
FUNCTION 135
OPERATION 137
ACCUMULATOR1 139
FUNCTION 139
SLACK ADJUSTER 140
FUNCTION 140
OPERATION 141
BRAKE 143
FUNCTION 143
OPERATION 143
PARKING BRAKE 144
OUTLINE 144
OPERATION 145
SPRING CYLINDER 146
OUTLINE 146
PARKING BRAKE SOLENOID VALVE 147
FUNCTION 147
HYDRAULIC PIPING 149
HYDRAULIC CIRCUIT DIAGRAM 152
WORK EQUIPMENT LEVER LINKAGE 154
HYDRAULIC TANK 155
OUTLINE 155
OIL FILTER BYPASS VALVE 156
BREATHER 157
FUNCTION 157
MAIN PISTON PUMP 158
OUTLINE 158
PISTON PUMP (HPV90 + 90) 159
FUNCTION 161
STRUCTURE 161
OPERATION 162
CONTROL PUMP (BAR025) 164
RELIEF VALVE 165
ES (ENGINE SENSING) VALVE 166
FUNCTION 166
SERVO VALVE 168
OPERATION 169
PPC VALVE 171
OPERATION 173
PPC RELIEF VALVE 175
FUNCTION 175
OPERATION 175
ACCUMULATOR (PPC VALVE) 176
MAIN CONTROL VALVE 177
FUNCTION 178
RELIEF VALVE 179
FUNCTION 179
OPERATION 179
SAFETY VALVE (with suction valve) 180
FUNCTION 180
OPERATION 180
SUCTION VALVE 181
OPERATION 181
FLOAT SELECTOR VALVE AND UNLOADER VALVE 182
FUNCTION 182
OPERATION 182
OPERATION OF HYDRAULIC CIRCUIT 184
BOOM AND DUMP SPOOLS IN “HOLD” 184
LIFT SPOOL IN “RAISE” 185
LIFT SPOOL IN “LOWER” 186
BOOM SPOOL IN “FLOAT” 187
DUMP SPOOL IN “DUMP” 188
DUMP SPOOL IN “TILT BACK” 189
WORK EQUIPMENT 191
LUBRICATION 191
LINKAGE 193
BUCKET POSITIONER AND BOOM KICKOUT 195
BUCKET POSITIONER 196
BOOM KICK-OUT 196
OPERATION OF PROXIMITY SWITCH 197
BOOM RAISE 197
BUCKET TILT 199
CAB 201
ROPS CANOPY 202
AIR CONDITIONER 203
AIR CONDITIONER PIPING 203
AIR CONDITIONER CONDENSER 204
AIR CONDITIONER COMPRESSOR 204
DRY RESERVOIR 205
ELECTRIC CIRCUIT DIAGRAM 206
MACHINE MONITOR SYSTEM 226
OUTLINE 226
MAIN MONITOR 227
OUTLINE 227
DISPLAY FUNCTION 228
SWITCH FUNCTION 229
TROUBLE DATA DISPLAY MODE 230
MAINTENANCE MONITOR 231
OUTLINE 231
DISPLAY FUNCTION 232
ENGINE START AND STOP CIRCUIT 233
SAFETY RELAY 235
FUNCTION 236
ENGINE START 236
ENGINE STOP 236
PREHEATING CIRCUIT 237
OUTLINE 237
ELECTRICAL TRANSMISSION CONTROL 238
FUNCTION 238
COMBINATION SWITCH 239
OUTLINE 239
OPERATION 240
KICK-DOWN, HOLD SWITCH 241
KICK-DOWN OPERATION 241
HOLD SWITCH OPERATION 241
PARKING BRAKE 242
ELECTRIC CONTROL 242
OUTLINE 242
FUNCTION 243
OPERATION 244
STARTING SWITCH OFF 244
STARTING SWITCH ON 245
PARKING BRAKE SWITCH OFF (released) 247
PARKING BRAKE SWITCH ON (actuated) 248
WHEN MAIN BRAKE OIL PRESSURE DROPS (emergency brake actuated) 249
PARKING BRAKE SOLENOID VALVE 250
PARKING SAFETY RELAY 250
NEUTRALIZER RELAY 250
EMERGENCY BRAKE SWITCH 250
20 TESTING, ADJUSTING AND TROUBLESHOOTING 252
STANDARD VALUE TABLE FOR ENGINE 253
STANDARD VALUE TABLE FOR CHASSIS 254
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 260
TESTING AND ADJUSTING 270
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 271
MEASURING ENGINE SPEED 273
MEASURING GAS COLOR 274
ADJUSTING VALVE CLEARANCE 275
MEASURING COMPRESSION PRESSURE 276
MEASURING BLOW-BY PRESSURE 277
FUEL INJECTION TIMING 278
MEASURING ENGINE OIL PRESSURE 280
MEASURING EXHAUST TEMPERATURE 281
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 282
ALTERNATOR BELT TENSION 283
AIR CONDITIONER COMPRESSOR BELT TENSION 284
MEASURING ACCELERATOR PEDAL 285
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE 286
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL 289
STEERING OIL PRESSURE 291
GROUND DRIVEN STEERING OIL PRESSURE 292
BLEEDING AIR FROM STEERING CIRCUIT 294
STEERING STOP VALVE 295
TESTING WHEEL BRAKE PERFORMANCE 296
TESTING WHEEL BRAKE OIL PRESSURE DROP 297
MEASURING WEAR OF WHEEL BRAKE DISC 299
ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE 300
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT 302
TESTING PARKING BRAKE PERFORMANCE 303
MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE 304
PARKING BRAKE PAD 305
PPC PRESSURE 307
ADJUSTING PPC VALVE LINKAGE 309
WORK EQUIPMENT HYDRAULIC PRESSURE 310
BLEEDING AIR FROM PISTON PUMP 312
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT 313
ADJUSTING WORK EQUIPMENT LEVER LINKAGE 314
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 316
BUCKET PROXIMITY SWITCH 316
BOOM PROXIMITY SWITCH 318
TESTING PROXIMITY ACTUATION PILOT LAMP 319
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR 320
ADJUSTING JOYSTICK LEVER POTENTIOMETER 321
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH 323
TROUBLESHOOTING 324
POINTS TO REMEMBER WHEN TROUBLESHOOTING 325
SEQUENCE OF EVENTS IN TROUBLESHOOTING 326
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 327
POINTS TO REMEMBER WHEN HANDLING ELECTRICAL EQUIPMENT 327
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 332
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 333
CHECKS BEFORE TROUBLESHOOTING 335
CONNECTOR TYPES AND MOUNTING LOCATIONS 336
CONNECTOR ARRANGEMENT DIAGRAM 340
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS 345
EXPLANATIONS OF ELECTRIC CONTROL MECHANISM 358
TRANSMISSION CONTROL SYSTEM 358
MAIN MONITOR SYSTEM 359
MAINTENANCE MONITOR SYSTEM 360
JOYSTICK STEERING 361
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE 362
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION 364
TRANSMISSION CONTROLLER LED DISPLAY 366
METHOD OF USING JUDGEMENT TABLE 367
METHOD OF USING TROUBLESHOOTING CHARTS 368
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 370
METHOD OF USING TROUBLESHOOTING ENGINE RELATED CHARTS 372
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 376
S-1 Starting performance is poor (Starting always takes time) 377
S-2 Engine does not start 378
(1) Engine does not turn 378
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected) 379
(3) Exhaust gas comes out but engine does not start 380
S-3 Engine does not pick up smoothly (Follow-up is poor) 381
S-4 Engine stops during operation 382
S-5 Engine does not rotate smoothly (Hunting) 383
S-6 Engine lacks output (No power) 384
S-7 Exhaust gas is black (Incomplete combustion) 385
S-8 Oil consumption is excessive (or exhaust gas it blue) 386
S-9 Oil become contaminated quickly 387
S-10 Fuel consumption is excessive 388
S-11 Oil in coolant water, or water spurts back or water level goes down 389
S-12 Oil pressure lamp light up (Drop in oil pressure) 390
S-13 Oil level rises 391
S-14 Coolant water temperature becomes too high (Overheating) 392
S-15 Abnormal noise is made 393
S-16 Vibration is excessive 394
TROUBLESHOOTING OF TRANSMISSION CONTOLLER SYSTEM (T-MODE) 396
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER 397
ACTION TAKEN BY CONTROLLER 399
ELECTRICAL DIAGRAM FOR TRANSMISSION CONTROLLER 404
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed 405
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed 406
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed 407
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed 408
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed 409
T-6 Failure code [16] (Short circuit, disconnection with power source in 3rd solenoid) is displayed 410
T-7 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed 411
T-8 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed 413
T-9 Failure code [21] (Short circuit, disconnection, engine speed sensor system) is displayed 417
T-10 Failure code [22] (Disconnection in travel speed sensor system) is displayed 420
T-11 Failure code [23] (Short circuit, disconnection, engine speed sensor system) is displayed 421
T-12 Shift-up signal system (Joystick (OP) manual shift) and hold signal system (Auto-shift (OP)) 422
T-13 Kick-down signal system and shift down signal system (Joystick (OP) manual shift) 422
T-14 Transmission cut-off signal system 423
T-15 Neutralizer signal system 424
T-16 Buzzer signal system 425
T-17 Network system 426
T-18 Transmission controller power source 427
T-19 Short circuit in travel speed sensor system 428
T-20 Abnormality in machine selection wire harness 429
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 430
Trouble data display 432
Electrical circuit diagram of machine monitor system 434
M-1 Main monitor does not work (backup lamp relay) is displayed 435
M-2 When starter switch is turned ON (within 3 seconds) and engine is started immediately, all lamps stay lit up 436
M-3 Speedometer display does not work properly 437
M-4 Abnormality in shift indicator 438
M-5 High beam display does not light up 441
M-6 Turn signal display does not light up 442
M-7 Abnormality in parking display 443
M-8 Abnormality in preheating system 444
M-9 Night lighting does not light up 448
M-10 Abnormality in front working lamp 449
M-11 Abnormality in rear working lamp 451
M-12 Abnormality in transmission cut-off 453
M-13 Abnormality in low idle selection 455
M-14 Abnormality in ground driven steering actuation display 457
M-15 Abnormality in parking brake dragging warning 458
M-16 Abnormality in parking brake dragging warning (When joystick steering mode (OP)) 460
M-17 When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated continuously, or not actuated 462
M-18 Abnormality in buzzer 463
M-19 Condition of monitor switches is not stored in memory 464
M-20 Abnormality in failure display mode 465
M-21 Buzzer is not made to sound by transmission & joystick steering controller 466
M-22 Abnormality in auto-greasing system (OP) 467
M-23 Failure code is not sent to main monitor (abnormality in network) (OP) 469
TROUBLESHOOTING OF MAINTENANCE MONITOR (K-MODE) 470
ELECTRICAL DIAGRAM MAINTENANCE MONITOR SYSTEM 472
K-1 When starter switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec, maintenance monitor does no 473
K-2 When starter switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 sec) 474
K-3 When engine is started immediately after starter switch is turned ON (within 3 sec), no lamps on maintenace go out 475
K-4 When starter switch is turned on (engine stopped), CHECK items Flash 476
K-5 When starter switch is turned ON (engine started), CAUTION items flash 478
K-6 CAUTION items are flashing but buzzer does not sound 485
K-7 There is not abnormality in monitor display but caution buzzer sounds 486
K-8 CAUTION items are flashing but neither CHECK lamp nor CAUTION lamp flashes 487
K-9 There is not abnormality in maintenance monitor display but CHECK lamp or CAUTION lamp light up 488
K-10 Only night lighting of maintenance monitor does not light up when light switch is turned ON 489
K-11 Night lighting lights up even when light switch is turned OFF 490
K-12 Service meter does not work 491
K-13 Service meter is running even when engine is stopped 491
K-14 Abnormality in gauge display 492
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 496
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND PREHEATING 498
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING 499
ENGINE PRE-LUBRICATION SYSTEM 500
ELECTRICAL DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER 504
E-1 Engine does not start 505
E-2 Engine does not stop (STD spec ) 510
E-3 Abnormaltiy in preheating system 512
E-4 Parking brake does not have effect 516
E-5 Parking brake is applied when machine is traveling 517
E-6 Parking brake is released when starting switch turned ON 519
E-7 Transmission does not change to neutral when parking brake is applied 519
E-8 Kick-down swiitch does not work 521
E-9 Boom kick-out does not work 523
E-10 Abnormality in bucket positioner function 527
E-11 Abnormality in lighting up of front working lamp 530
E-12 Abnormality in lighting up of rear working lamp 530
E-13 Abnormality in transmission cut-off 530
E-14 Abnormality in low idle selection 530
E-15 Abnormality in parking brake dragging warning 530
E-16 Abnormality in buzzer 530
TROUBLESHOOTING OF ELECTRICAL SYSTEM (H-MODE) 532
H-1 Machine does not move 533
H-2 Machine lacks power or speed (every speed range) 534
H-3 Excessive time lag when starting machine or shifting gear 535
H-4 Torque converter oil temperature is high 536
H-5 Steering does not turn 537
H-6 Steering does not turn [machine with joystick (OP)] 538
H-7 Turning, response of steering is poor 539
H-8 Turning, response of steering is poor [machine with joystick (OP)] 540
H-9 Steering is heavy 541
H-10 Joystick is heavy [machine with joystick (OP)] 541
H-11 Steering wheel shakes or jerks 542
H-12 Steering wheel shakes or jerks shock [machine with joystick (OP)] 543
H-13 Turning radius is different between left and right at maximum steering 543
H-14 Wheel brakes do not work or braking effect is poor 544
H-15 Wheel brakes are not released or brakes drag 545
H-16 Boom does not rise 546
H-17 Boom moves slowly or does not have sufficient lifting power 547
H-18 When raising boom, becomes slow at certain height 548
H-19 Boom cylinder cannot hold down bucket 548
H-20 Boom has great amount of hydraulic drift 548
H-21 Boom fluctuates while working 549
H-22 Boom drops momentarily when lever is operated from HOLD to RAISE 549
H-23 Bucket does not tilt back 550
H-24 Bucket moves slowly and has insufficient tilt back power 551
H-25 Bucket movement becomes slow during tilt back 552
H-26 Bucket cylinder cannot hold down bucket 552
H-27 Bucket has large amount of hydraulic drift 552
H-28 Bucket fluctuates while traveling under load 553
H-29 Bucket dumps momentarily when lever is operated from HOLD to TILT 553
H-30 Boom and bucket levers do not move smoothly 554
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM 556
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM 557
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS 559
ELECTRICAL DIAGRAM FOR JOYSTICK STEERING SYSTEM 563
J-1 Failure code [56] (short circuit, disconnection in caution relay output) is displayed 565
J-2 Failure code [57] (short circuit in steering right solenoid (detected when signal is output)) is displayed 566
J-3 Failure code [58] (short circuit in steering left solenoid (detected when signal is output)) is displayed 567
J-4 Failure code [59] (short circuit in steering right solenoid (power supply side)) is displayed 568
J-5 Failure code [60] (short circuit in steering left solenoid (power supply side)) is displayed 569
J-6 Failure code [61] (short circuit, disconnection in steering right solenoid cut relay output) is displayed 570
J-7 Failure code [62] (short circuit, disconnection in joystick steering neutral circuit 571
J-8 Failure code [63] (short circuit, disconnection in joystick steering lever potentiometer) 572
J-9 Abnormality in power supply, power supply voltage 573
J-10 Abnormality in joystick steering ON-OFF circuit 574
J-11 Disconnection in steering right solenoid 575
J-12 Disconnecion in steering left solenoid 576
30 DISASSEMBLY AND ASSEMBLY 578
METHOD OF USING MANUAL 582
PRECAUTIONS DURING OPERATION 583
Precautions when carrying out removal work 583
Precautions when carrying out installation work 584
Precautions when completing the operations 585
Other precautions 585
SPECIAL TOOL LIST 586
SKETCHES OF SPECIAL TOOLS 594
ENGINE 602
ALTERNATOR 602
CYLINDER HEAD 602
DAMPER 602
ENGINE OIL COOLER 602
ENGINE FRONT SEAL 602
ENGINE REAR SEAL 602
FUEL INJECTION PUMP FOR LEFT BANK 602
FUEL INJECTION PUMP FOR RIGHT BANK 602
NOZZLE HOLDER 602
STARTING MOTOR 602
TURBOCHARGER 602
WATER PUMP 602
RADIATOR 603
REMOVAL 603
INSTALLATION 606
ENGINE 607
REMOVAL 607
INSTALLATION 613
TORQUE CONVERTER & TRANSMISSION 614
REMOVAL 614
INSTALLATION 622
TORQUE CONVERTER 624
DISASSEMBLY 624
ASSEMBLY 628
TORQUE CONVERTER VALVE 633
DISASSEMBLY 633
ASSEMBLY 633
TRANSMISSION 634
DISASSEMBLY 634
ASSEMBLY 650
TRANSMISSION VALVE 666
REMOVAL 666
INSTALLATION 666
UPPER VALVE 667
DISASSEMBLY 667
ASSEMBLY 668
LOWER VALVE 669
DISASSEMBLY 669
ASSEMBLY 669
RELIEF VALVE 670
DISASSEMBLY 670
ASSEMBLY 670
TRANSFER 671
DISASSEMBLY 671
ASSEMBLY 679
PTO 689
DISASSEMBLY 689
ASSEMBLY 691
CENTER SUPPORT 694
REMOVAL 694
INSTALLATION 695
DISASSEMBLY 696
ASSEMBLY 698
DRIVE SHAFT 701
DISASSEMBLY 701
ASSEMBLY 703
FRONT AXLE 705
REMOVAL 705
INSTALLATION 707
REAR AXLE 708
REMOVAL 708
INSTALLATION 714
DIFFERENTIAL 716
REMOVAL 716
INSTALLATION 718
DISASSEMBLY 719
ASSEMBLY 723
FINAL DRIVE 729
DISASSEMBLY 729
ASSEMBLY 732
ORBIT-ROLL 735
REMOVAL 735
INSTALLATION 736
GROUND DRIVEN STEERING PUMP 737
REMOVAL 737
INSTALLATION 737
DIVERTER VALVE 738
REMOVAL 738
INSTALLATION 738
DISASSEMBLY 739
ASSEMBLY 740
ACCUMULATOR CHARGE VALVE 742
REMOVAL 742
INSTALLATION 742
DISASSEMBLY 743
ASSEMBLY 744
STEERING STOP VALVE 746
REMOVAL 746
INSTALLATION 746
STEERING CYLINDER 747
REMOVAL 747
INSTALLATION 748
STEERING VALVE 749
REMOVAL 749
INSTALLATION 750
BRAKE VALVE 751
REMOVAL 751
INSTALLATION 751
SLACK ADJUSTER 752
REMOVAL 752
INSTALLATION 752
DISASSEMBLY 753
ASSEMBLY 754
BRAKE 755
REMOVAL 755
INSTALLATION 756
DISASSEMBLY 757
ASSEMBLY 760
PARKING BRAKE CALIPERS 764
REMOVAL 764
INSTALLATION 765
DISASSEMBLY 766
ASSEMBLY 768
PARKING BRAKE PAD 770
REMOVAL 770
INSTALLATION 771
PARKING BRAKE SPRING CYLINDER 772
REMOVAL 772
INSTALLATION 772
BRAKE OIL TANK 773
REMOVAL 773
INSTALLATION 773
HYDRAULIC PUMP 774
REMOVAL 774
INSTALLATION 776
HYDRAULIC TANK AND FILTER CASE 777
REMOVAL 777
INSTALLATION 778
PPC VALVE 779
REMOVAL 779
INSTALLATION 780
DISASSEMBLY 781
ASSEMBLY 781
WORK EQUIPMENT CONTROL VALVE 782
REMOVAL 782
INSTALLATION 783
DISASSEMBLY 784
ASSEMBLY 786
CAB 788
REMOVAL 788
INSTALLATION 791
FLOOR FRAME 792
REMOVAL 792
INSTALLATION 795
CENTER HINGE PIN 796
REMOVAL 796
INSTALLATION 802
WORK EQUIPMENT 806
REMOVAL 806
INSTALLATION 811
BOOM FRONT END BUSHING 812
REPLACEMENT 812
BUCKET CYLINDER 813
REMOVAL 813
INSTALLATION 813
LIFT CYLINDER 814
REMOVAL 814
INSTALLATION 815
HYDRAULIC CYLINDER 816
DISASSEMBLY 816
ASSEMBLY 818
AIR CONDITIONER UNIT 820
REMOVAL 820
INSTALLATION 821
AIR CONDITIONER COMPRESSOR 822
REMOVAL 822
INSTALLATION 822
RECEIVER TANK 823
REMOVAL 823
INSTALLATION 823
AIR CONDITIONER CONDENSER 824
REMOVAL 824
INSTALLATION 825
TRANS AND STEERING CONTROLLER 826
REMOVAL 826
INSTALLATION 826
MAIN MONITOR 827
REMOVAL 827
INSTALLATION 828
FUEL TANK 829
REMOVAL 829
INSTALLATION 830
COUNTERWEIGHT 831
REMOVAL 831
INSTALLATION 833
40 MAINTENANCE STANDARD 834
ENGINE MOUNT 835
TRANSMISSION MOUNT 836
DAMPER 837
HYDRAULIC PUMPS 839
TORQUE CONVERTER CHARGING, PPC AND BRAKE 839
TORQUE CONVERTER 841
TORQUE CONVERTER REGULATOR VALVE 842
TRANSMISSION 843
CLUTCH 843
GEAR 845
TRANSFER 846
TRANSMISSION CONTROL VALVE 847
UPPER VALVE 847
LOWER VALVE 849
SOLENOID VALVE 851
DRIVE SHAFT 852
CENTER SUPPORT 853
DIFFERENTIAL 854
ASSEMBLY TORQUES 854
DIFFERENTIAL 855
GEARS 855
FINAL DRIVE 857
AXLE MOUNT 859
CENTER HINGE PIN 861
STEERING COLUMN 863
STEERING DEMAND VALVE 864
DIVERTER VALVE 866
STEERING CYLINDER MOUNT 867
GROUND DRIVEN STEERING PUMP 868
BRAKE VALVE 869
SLACK ADJUSTER 871
BRAKE 873
PARKING BRAKE 875
PPC VALVE 877
PPC RELIEF VALVE 879
CONTROL PUMP (BAR025) 880
MAIN CONTROL VALVE 881
HYDRAULIC CYLINDER 884
BUCKET LINKAGE 885
BUCKET POSITIONER AND BOOM KICK-OUT 887
90 OTHERS (shop manual foldouts) 889
Foldout 10-107 Hydraulic circuit diagram 891
Foldout 10-161 Electrical circuit diagram (1 of 2) (sheet 1 of 6) 893
Foldout 10-161 Electrical circuit diagram (1 of 2) (sheet 2 of 6) 895
Foldout 10-161 Electrical circuit diagram (1 of 2) (sheet 3 of 6) 897
Foldout 10-161 Electrical circuit diagram (1 of 2) (sheet 4 of 6) 899
Foldout 10-161 Electrical circuit diagram (1 of 2) (sheet 5 of 6) 901
Foldout 10-161 Electrical circuit diagram (1 of 2) (sheet 6 of 6) 903
Foldout 10-173 Electrical circuit diagram (2 of 2) (sheet 1 of 4) 905
Foldout 10-173 Electrical circuit diagram (2 of 2) (sheet 2 of 4) 907
Foldout 10-173 Electrical circuit diagram (2 of 2) (sheet 3 of 4) 909
Foldout 10-173 Electrical circuit diagram (2 of 2) (sheet 4 of 4) 911
Foldout 20-217 Connector arrangement diagram (1 of 3) 913
Foldout 20-219 Connector arrangement diagram (2 of 3) 915
Foldout 20-409 Electrical diagram for transmission controller 917
Foldout 20-505 Electrical diagram for transmission controller (sheet 1 of 4) 919
Foldout 20-505 Electrical diagram for transmission controller (sheet 2 of 4) 921
Foldout 20-505 Electrical diagram for transmission controller (sheet 3 of 4) 923
Foldout 20-505 Electrical diagram for transmission controller (sheet 4 of 4) 925
Foldout 20-603 Electrical circuit diagram for maintenance monitor system 927
Foldout 20-703 Electrical circuit diagram for power supply, engine starting, engine stopping, and preheating 929

DESCRIPTION:

Komatsu Avance WA800-3LC Wheel Loader Shop Manual CEBM003803 – PDF DOWNLOAD

• SERIAL NUMBERS WA800-3LC A50001 and UP

GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into the following sections. These sections are further
divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and
fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes”
are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.

G.B  16/12/24