Komatsu WA600-1 Wheel Loader Shop Manual CEBM000800 PDF

Description

Komatsu WA600-1 Wheel Loader Shop Manual CEBM000800 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA600-1 Wheel Loader Shop Manual CEBM000800 – PDF DOWNLOAD 

Language : English
Pages : 953
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA600-1 Wheel Loader Shop Manual CEBM000800 – PDF DOWNLOAD 

SERIAL NUMBERS WA6004LE – A51001 andup

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu WA600-1 Wheel Loader Shop Manual CEBM000800 – PDF DOWNLOAD 

SERIAL NUMBERS WA6004LE – A51001 andup

MAIN MENU 0
CONTENTS 2
01 GENERAL 21
GENERAL SPECIFICATIONS – STANDARD BOOM 22
GENERAL SPECIFICATIONS – HI- LIFT BOOM 23
DIMENSIONS 24
SPECIFICATIONS 26
WEIGHT TABLE 29
FUEL, COOLANT, AND LUBRICANTS 30
ENGINE OIL SPECIFICATIONS 31
TRANSMISSION, HYDRAULIC SYSTEM AND BRAKE SYSTEM OIL 32
AXLE OIL SPECIFICATIONS 32
GREASE SPECIFICAITONS 32
DIESEL FUEL SPECIFICATIONS 32
COOLANT SPECIFICATIONS 32
10 STRUCTURE AND FUNCTION 39
GENERAL (POWER TRAIN) 41
POWER TRAIN 42
HYDRAULIC CIRCUIT FOR POWER TRAIN 44
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 45
TORQUE CONVERTER, TRANSMISSION PIPING 46
TORQUE CONVERTER OIL COOLER 47
TORQUE CONVERTER 48
TORQUE CONVERTER RELIEF VALVE 51
TORQUE CONVERTER REGULATOR VALVE 52
TORQUE CONVERTER OIL FILTER 54
LUBRICATION BY-PASS VALVE 55
TRANSMISSION MOUNT 56
TRANSMISSION 58
TRANSMISSION CONTROL VALVE 64
TRANSMISSION SOLENOID VALVE 76
EMERGENCY MANUAL SPOOL 78
TRANSMISSION PILOT OIL FILTER 79
TRANSFER 80
DRIVE SHAFT 81
CENTER SUPPORT 82
AXLE MOUNT 84
AXLES 86
DIFFERENTIAL 88
FINAL DRIVE 92
TIRE AND WHEEL 93
GENERAL (STEERING) 94
STEERING COLUMN, GEAR BOX, AND LINKAGE 96
HYDRAULIC CIRCUIT FOR STEERING 98
STEERING CONTROL SYSTEM 100
TWO-WAY RESTRICTOR VALVE 110
STEERING CYLINDER 111
CENTER HINGE PIN 112
GROUND DRIVEN STEERING 113
GENERAL (BRAKE AND AIR SYSTEM) 118
BRAKE AND AIR PIPING 119
BRAKE AND AIR CIRCUIT SYSTEM 120
AIR TANKS 121
BRAKE VALVE 122
TWO-WAY VALVE 126
RELAY VALVE 127
BRAKE CHAMBER 128
SLACK ADJUSTER 130
BRAKE 134
PARKING BRAKE 136
BRAKE CALIPER 138
PARKING BRAKE SOLENOID VALVE 139
SPRING CYLINDER 140
HYDRAULIC TANK PRESSURIZING VALVE 141
GENERAL (HYDRAULIC WORK EQUIPMENT) 142
HYDRAULIC PIPING 143
HYDRAULIC CIRCUIT SCHEMATIC 144
HYDRAULIC CIRCUIT DIAGRAM 146
HYDRAULIC TANK 148
HYDRAULIC PUMPS 152
GENERAL (GEAR PUMPS) 154
PRINCIPLE OF OPERATION 155
PRESSURE LOADED TYPE GEAR PUMP 158
FIXED SIDE PLATE TYPE GEAR PUMP 160
SA SERIES TYPE GEAR PUMP 161
PROPORTIONAL PRESSURE CONTROL (PPC) VALVE 166
PPC RELIEF VALVE 170
MAIN CONTROL VALVE 171
FLOAT SELECTOR AND UNLOADER VALVE 177
ACCUMULATOR (FOR WORK EQUIPMENT) 179
HYDRAULIC CIRCUIT OPERATION 180
HYDRAULIC CYLINDERS (BUCKET AND BOOM) 188
BUCKET LINKAGE 190
BUCKET POSITIONER AND BOOM KICK-OUT 192
WORK EQUIPMENT LEVER LINKAGE 194
BUCKET 195
ELECTRICAL WIRING DIAGRAM 197
ENGINE STARTING CIRCUIT 202
ENGINE STOP CIRCUIT 204
ETHER START CIRCUIT 205
ELECTRIC TRANSMISSION CONTROL 206
COMBINATION SWITCH 207
TRANSMISSION CUT-OFF SWITCH 208
TRANSMISSION CUT-OFF SELECTOR SWITCH 209
NEUTRALIZER SWITCH 210
KICK-DOWN SWITCH 211
KICK-DOWN ELECTRIC CIRCUIT 212
ELECTRIC PARKING BRAKE CONTROL 218
PROXIMITY SWITCH 228
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) 236
SENSORS 242
AIR CONDITIONING (GENERAL) 252
AIR CONDITIONING PIPING DIAGRAM 262
AIR CONDITIONING CONDENSER 263
RECEIVER W/SIGHT GLASS (LIQUID TANK) 265
AIR CONDITIONER UNIT 267
AIR CONDITIONER CONTROL PANEL 268
ENGINE DIAGNOSTIC SYSTEM 270
ENGINE DIAGNOSTIC ELECTRICAL SCHEMATIC 275
20 TESTING AND ADJUSTING 277
STANDARD VALUE TABLE – ENGINE 279
STANDARD VALUE TABLE – CHASSIS 280
STANDARD VALUE TABLE – ELECTRICAL SYSTEM 284
TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING 288
MEASURING ENGINE SPEEDS 290
MEASURING INTAKE MANIFOLD PRESSURE 291
MEASURING INTAKE AIR RESTRICTION 292
MEASURING ENGINE LUBRICATING OIL PRESSURE 293
MEASURING FUEL FILTER INLET RESTRICTION 294
MEASURING BLOW-BY PRESSURE 295
MEASURING EXHAUST BACK PRESSURE 296
MEASURING COOLANT TEMPERATURE 297
MEASURING AND ADJUSTING VALVE CLEARANCE 298
ALTERNATOR FAN BELT 299
FAN BELT TENSIONER 300
ENGINE OIL PRESSURE 301
EXHAUST OIL TEMPERATURE 302
EXHAUST GAS COLOR 304
MEASURING ENGINE STALL SPEEDS 306
ACCELERATOR PEDAL 308
MEASURING SHIFT LEVERS 309
MEASURING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE 310
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL 312
TIRES AND WHEELS 314
MEASURING STEERING WHEEL PLAY 315
MEASURING STEERING WHEEL OPERATING FORCE 316
OPERATING TIME OF STEERING WHEEL 317
STEERING OIL PRESSURE 318
STEERING LINKAGE 320
MEASURING BRAKE PEDAL 323
MEASURING AIR PRESSURE 324
BRAKE PERFORMANCE 326
CHECKING BRAKE OIL PRESSURE 327
MEASURING WEAR OF BRAKE DISC 328
AIR BLEEDING FROM BRAKE LINE 329
PARKING BRAKE PERFORMANCE 330
CHECKING AND ADJUSTING PARKING BRAKE 331
MEASURING BUCKET AND BOOM CONTROL LEVERS 333
ADJUSTING BUCKET AND BOOM CONTROL LEVERS 334
HYDRAULIC CIRCUIT FLUSHING 336
PPC RELIEF VALVE PRESSURE 340
WORK EQUIPMENT RELIEF VALVE 342
MEASURING WORK EQUIPMENT OPERATING SPEEDS 344
WORK EQUIPMENT HYDRAULIC DRIFT 345
BUCKET POSITIONER 346
BOOM KICK-OUT 347
MACHINE MONITOR (SPEEDOMETER MODULE) 348
TROUBLESHOOTING 349
POINTS TO REMEMBER WHEN TROUBLESHOOTING 352
SEQUENCE OF EVENTS IN TROUBLESHOOTING 353
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 354
CHECKS BEFORE TROUBLESHOOTING 362
HANDLING CONNECTORS 363
PRECAUTIONS WHEN TROUBLESHOOTING 364
PREVENTING RECURRENCE OF TROUBLE 368
JUDGEMENT ON POWER TRAIN (T-1 -T-4) 370
TROUBLESHOOTING TABLES (POWER TRAIN, T-1 – T-4) 372
Machine does not move 372
Machine lacks power or speed 374
Excessive time lag when starting machine or shifting gear 375
Torque converter oil temperature too high 376
TROUBLESHOOTING TABLES (STEERING SYSTEM) 377
1 Steering wheel does not turn 377
2 Steering wheel is sluggish 378
3 Steering wheel moves unsteadily or is subject to large shock 379
4 Machine tends to turn naturally in one particular direction when traveling 379
5 Left and right turning radii are different 379
TROUBLESHOOTING TABLES (BRAKE AND AIR SYSTEM) 380
1 Air pressure does not rise at all 380
2 Air pressure does not rise to the specified range 381
3 Brake is ineffective or not very effective 382
4 Brake does not release, or drags 383
5 Parking brake does not release, or drags 384
TROUBLESHOOTING TABLES (WORK EQUIPMENT SYSTEM) 385
1 Lift arm does not rise 385
2 Lift arm moves slowly or does not have sufficient lifting power 386
3 Lift arm movement becomes slow after it reaches a certain height 387
4 Bucket cannot be held down with lift arm cylinder 387
5 Lift arm has large hydraulic drift 387
6 Lift arm movement is unsteady during work 387
7 Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise” 387
8 Bucket does not tilt back 388
9 Bucket moves slowly or has insufficient tilt back power 389
10 Bucket movement becomes slow during tilt back 390
11 Bucket cannot be held down by the bucket cylinder 390
12 Bucket has large hydraulic drift 390
13 Bucket moves unsteadily when machine travels under load (Main control valve in “Hold”) 390
14 Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back” 390
15 Control levers of lift arm and dump move stiffly and sluggishly 391
TROUBLESHOOTING TABLES (ELECTRICAL SYSTEM) 392
JUDGMENT ON POWER TRAIN (ELECTRICAL E-8 – E-13) 392
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART 394
PRECAUTION WHEN HANDLING CONNECTORS 396
CONNECTOR TERMINAL NUMBERS 398
ELECTRICAL WIRING DIAGRAM 405
ELECTRICAL CIRCUIT DIAGRAM 409
VEHICLE MONITOR ELECTRICAL DIAGRAM 410
ELECTRICAL CIRCUIT SYSTEM 412
ENGINE STARTING AND STOP CIRCUIT DIAGRAM 412
TRANSMISSION CONTROL, PARKING CIRCUIT DIAGRAM 413
PARKING BRAKE CIRCUIT DIAGRAM 414
KICK-DOWN CIRCUIT DIAGRAM 415
ETHER INJECTION CIRCUIT DIAGRAM 416
TROUBLESHOOTING CHART FOR ELECTRICAL SYSTEM 417
POSITION OF CONNECTORS FOR TROUBLESHOOTING 417
E-1 ENGINE DOES NOT START 424
E-2 ENGINE DOES NOT STOP 426
E-3 ENGINE STOPS WHEN TRAVELING 427
E-4 PARKING BRAKE DOES NOT WORK 428
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING 430
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 432
E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED 433
E-8 TRANSMISSION DOES NOT WORK NORMALLY 434
E-9 KICK-DOWN SWITCH DOES NOT WORK 456
E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON 459
E-11 KICK-DOWN OPERATION IS NOT CANCELED 460
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2 462
E-13 MACHINE NOT TRAVEL WHEN 462
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM 465
POSITION OF CONNECTORS FOR TROUBLESHOOTING 466
M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED 474
M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED 474
M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED 476
M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING 476
M-5 (TRANSMISSION OIL FILTER ENGINE IS RUNNING 478
M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING 480
M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING 480
M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING 482
M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING 482
M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING 484
M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING 484
M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING 484
M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP 486
M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP 488
M-15 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP 490
M-16 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT UP 492
M-17 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON 497
M-18 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY 498
M-19 HOURMETER DISPLAY DOES NOT WORK NORMALLY 499
M-20 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS 500
M-21 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT 501
M-22 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED 502
M-23 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP 504
M-24 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), SOUND 508
M-25 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS 508
M-26 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC T 510
M-27 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP 511
M-28 ABNORMALITY IN THE FUEL GAUGE SYSTEM 512
M-29 ABNORMALITY IN THE AIR PRESSURE GUAGE SYSTEM 514
M-30 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM 516
M-31 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM 518
EAGLE HEATER/AIR CONDITIONING 520
TROUBLESHOOTING 520
WIRING DIAGRAM 524
CONNECTOR DETAIL 524
30 DISASSEMBLY AND ASSEMBLY 525
STARTING MOTOR 528
REMOVAL 528
INSTALLATION 528
ALTERNATOR 529
REMOVAL 529
INSTALLATION 529
ENGINE OIL COOLER 530
REMOVAL 530
INSTALLATION 530
FUEL INJECTION PUMP 531
REMOVAL 531
INSTALLATION 531
WATER PUMP 532
REMOVAL 532
INSTALLATION 532
NOZZLE HOLDER 533
REMOVAL 533
INSTALLATION 533
TURBOCHARGER 534
REMOVAL 534
INSTALLATION 534
AIR COMPRESSOR 536
REMOVAL 536
INSTALLATION 537
CYLINDER HEAD 538
REMOVAL 538
INSTALLATION 540
RADIATOR 542
REMOVAL 542
INSTALLATION 545
ENGINE 548
REMOVAL 548
INSTALLATION 556
FUEL TANK 564
REMOVAL 564
INSTALLATION 566
TORQUE CONVERTER CHARGING AND PPC PUMP 569
REMOVAL 569
INSTALLATION 572
TORQUE CONVERTER 575
REMOVAL 575
INSTALLATION 579
TORQUE CONVERTER ASSEMBLY 584
DISASSEMBLY 584
ASSEMBLY 589
TRANSMISSION 595
REMOVAL 595
INSTALLATION 600
DISASSEMBLY 606
ASSEMBLY 621
TRANSFER 637
DISASSEMBLY 637
ASSEMBLY 646
TRANSMISSION CONTROL VALVE 658
REMOVAL 658
INSTALLATION 659
SPEED VALVE ASSEMBLY (TRANSMISSION CONTROL) 660
DISASSEMBLY 660
ASSEMBLY 660
MODULATING VALVE ASSEMBLY 662
DISASSEMBLY 662
ASSEMBLY 662
MAIN RELIEF VALVE ASSEMBLY 664
DISASSEMBLY 664
ASSEMBLY 664
FRONT AXLE 666
REMOVAL 666
INSTALLATION 668
REAR AXLE 670
REMOVAL 670
INSTALLATION 674
FRONT DIFFERENTIAL 678
REMOVAL 678
INSTALLATION 680
REAR DIFFERENTIAL 683
REMOVAL 683
INSTALLATION 686
DIFFERENTIAL GEAR 690
DISASSEMBLY 690
ASSEMBLY 694
FINAL DRIVE 701
DISASSEMBLY 701
ASSEMBLY 704
CENTER SUPPORT 708
REMOVAL 708
INSTALLATION 709
DISASSEMBLY 712
ASSEMBLY 714
DRIVE SHAFT 716
DISASSEMBLY 716
ASSEMBLY 718
STEERING, SWITCH PUMP 722
REMOVAL 720
INSTALLATION 722
STEERING GEAR 726
REMOVAL 726
INSTALLATION 728
STEERING GEAR BOX 729
DISASSEMBLY 729
ASSEMBLY 730
STEERING VALVE 733
REMOVAL 733
INSTALLATION 735
DISASSEMBLY 738
ASSEMBLY 739
STEERING CYLINDER 740
REMOVAL 740
INSTALLATION 742
DISASSEMBLY 744
ASSEMBLY 746
CENTER HINGE PIN 749
REMOVAL 749
INSTALLATION 758
AIR GOVERNOR 768
DISASSEMBLY 768
ASSEMBLY 769
BRAKE VALVE 770
REMOVAL 770
INSTALLATION 772
DISASSEMBLY 774
ASSEMBLY 776
BRAKE CHAMBER 778
REMOVAL 778
INSTALLATION 781
DISASSEMBLY 784
ASSEMBLY 787
SLACK ADJUSTER 790
REMOVAL 790
INSTALLATION 790
DISASSEMBLY 791
ASSEMBLY 792
BRAKE ASSEMBLY 794
REMOVAL 794
INSTALLATION 796
DISASSEMBLY 800
ASSEMBLY 803
SPRING CYLINDER 808
REMOVAL 808
INSTALLATION 809
DISASSEMBLY 810
ASSEMBLY 811
PARKING BRAKE 812
REMOVAL 812
INSTALLATION 815
PARKING BRAKE PAD 818
REMOVAL 818
INSTALLATION 818
HYDRAULIC TANK 820
REMOVAL 820
INSTALLATION 822
HYDRAULIC FILTER 824
REMOVAL 824
INSTALLATION 825
WORK EQUIPMENT PUMP 826
REMOVAL 826
INSTALLATION 829
PPC VALVE ASSEMBLY 832
REMOVAL 832
INSTALLATION 834
DISASSEMBLY 836
ASSEMBLY 836
MAIN CONTROL VALVE 838
REMOVAL 838
INSTALLATION 841
DISASSEMBLY 844
ASSEMBLY 846
BUCKET CYLINDER 848
REMOVAL 848
INSTALLATION 851
BOOM CYLINDER 853
REMOVAL 853
INSTALLATION 856
BOOM AND BUCKET CYLINDERS 859
DISASSEMBLY 859
ASSEMBLY 861
WORK EQUIPMENT 863
REMOVAL 863
INSTALLATION 869
COUNTERWEIGHT 876
REMOVAL 876
INSTALLATION 878
MACHINE MONITOR 880
REMOVAL 880
INSTALLATION 881
40 MAINTENANCE STANDARD 883
ENGINE MOUNT 884
TRANSMISSION MOUNT 885
TORQUE CONVERTER 886
TORQUE CONVERTER REGULATOR VALVE 888
TRANSMISSION 890
TRANSMISSION CONTROL VALVE (UPPER VALVE) 893
TRANSMISSION CONTROL VALVE (LOWER VALVE) 896
TRANSMISSION CONTROL VALVE (SOLENOID VALVE) 898
TRANSFER 900
DRIVE SHAFTS 902
CENTER SUPPORT 904
AXLE MOUNT 906
DIFFERENTIAL 908
FINAL DRIVE 912
STEERING COLUMN AND GEAR BOX 914
STEERING VALVE 916
STEERING CYLINDER MOUNT 918
STEERING CYLINDER 919
CENTER HINGE PIN 920
GROUND DRIVEN STEERING PUMP 923
DIVERTER VALVE 924
BRAKE VALVE 926
BRAKE CHAMBER 928
SLACK ADJUSTER 929
BRAKE 930
PARKING BRAKE 932
SPRING CYLINDER 934
MAIN CONTROL VALVE 936
TRANSMISSION LUBRICATION (SAL125) + TORQUE CONVERTER (SAL100) + PPC PUMP (SAL20) 938
STEERING (SAL 125) + SWITCH PUMP (SAL 100) 940
PPC VALVE 942
BUCKET CYLINDER 944
BOOM CYLINDER 946
BUCKET LINKAGE 948
BUCKET POSITIONER AND BOOM KICK-OUT 950
BUCKET 951

S.V 14/12/24