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Komatsu WA800-3LC Avance Loader A50001 and up Wheel Loader Shop Manual – PDF DOWNLOAD
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Komatsu WA800-3LC Avance Loader A50001 and up Wheel Loader Shop Manual
SERIAL NUMBERS WA800-3LC A50001 and UP
Book Code: CEBM003803
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Description
Komatsu WA800-3LC Avance Loader A50001 and up Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA800-3LC Avance Loader A50001 and up Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA800-3LC Avance Loader
Serial Number: A50001 and up
Book Code: CEBM003803
Language: English
Pages: 931
File Format: Portable Document Format (PDF)
KOMATSU WA800-3LC AVANCE LOADER A50001 AND UP WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA800-3LC Avance Loader A50001 and up Wheel Loader Shop Manual
FOREWORD:
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 AND ADJUSTING:
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.
TABLE OF CONTENTS:
Komatsu WA800-3LC Avance Loader A50001 and up Wheel Loader Shop Manual
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
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2 reviews for Komatsu WA800-3LC Avance Loader A50001 and up Wheel Loader Shop Manual – PDF DOWNLOAD
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Jones –
Moises Jett –
Immediate delivery after payment, manual as described. Will be very helpful with repair.