Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Komatsu WD600-1 Service Manual SEBM041E0104 PDF Download
$35.95
KOMATSU WD600-1 SHOP MANUAL SEBM041E0104 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU WD600-1 SHOP MANUAL SEBM041E0104 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WD600-1 SHOP MANUAL SEBM041E0104 – PDF DOWNLOAD
Language : English
Pages : 742
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WD600-1 SHOP MANUAL SEBM041E0104 – PDF DOWNLOAD
MAIN MENU........................................................................................................................................... 0 COVER............................................................................................................................................... 1 CONTENTS............................................................................................................................................ 2 10 ENGINE........................................................................................................................................... 18 11 STRUCTURE AND FUNCTION....................................................................................................................... 18 ENGINE LOW IDLING SELECT SYSTEM............................................................................................................. 19 12 TESTING AND ADJUSTING........................................................................................................................ 20 TABLE OF JUDGEMENT STANDARD VALUE .......................................................................................................... 21 ADJUSTING VALVE CLEARANCE................................................................................................................... 23 MEASURING COMPRESSION PRESSURE ............................................................................................................. 24 TESTING AND ADJUSTING FUEL INJECTION TIMING ................................................................................................ 25 MEASURING BLOW-BY PRESSURE ................................................................................................................. 27 TESTING AND ADJUSTING ALTERNATOR DRIVE BELT TENSION......................................................................................... 28 MEASURING EXHAUST GAS COLOR ................................................................................................................ 29 MEASEURING ENGINE OIL PRESSURE AND TEMPERATURE ............................................................................................. 30 MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE ............................................................................ 31 13 DISASSEMBLY AND ASSEMBLY..................................................................................................................... 34 STARTING MOTOR.............................................................................................................................. 35 REMOVAL................................................................................................................................. 35 INSTALLATION............................................................................................................................ 35 ALTERNATOR.................................................................................................................................. 36 REMOVAL................................................................................................................................. 36 INSTALLATION............................................................................................................................ 36 OIL COOLER.................................................................................................................................. 37 REMOVAL................................................................................................................................. 37 INSTALLATION............................................................................................................................ 37 FUEL INJECTION PUMP......................................................................................................................... 38 REMOVAL................................................................................................................................. 38 INSTALLATION............................................................................................................................ 38 WATER PUMP.................................................................................................................................. 39 REMOVAL................................................................................................................................. 39 INSTALLATION............................................................................................................................ 39 NOZZLE HOLDER............................................................................................................................... 40 REMOVAL................................................................................................................................. 40 INSTALLATION............................................................................................................................ 40 TURBOCHARGER................................................................................................................................ 41 REMOVAL................................................................................................................................. 41 INSTALLATION............................................................................................................................ 41 AIR COMPRESSOR.............................................................................................................................. 42 REMOVAL................................................................................................................................. 42 INSTALLATION............................................................................................................................ 42 CYLINDER HEAD............................................................................................................................... 43 REMOVAL................................................................................................................................. 43 INSTALLATION............................................................................................................................ 48 RADIATOR.................................................................................................................................... 54 REMOVAL................................................................................................................................. 54 INSTALLATION............................................................................................................................ 57 ENGINE...................................................................................................................................... 60 REMOVAL................................................................................................................................. 60 INSTALLATION............................................................................................................................ 67 FUEL TANK................................................................................................................................... 74 REMOVAL................................................................................................................................. 74 INSTALLATION............................................................................................................................ 76 20 POWER TRAIN...................................................................................................................................... 78 21 STRUCTURE AND FUNCTION....................................................................................................................... 78 GENERAL .................................................................................................................................... 79 • LOCATION OF COMPONENTS ............................................................................................................... 79 • POWER TRAIN .......................................................................................................................... 80 • HYDRAULIC CIRCUIT SCHEMATICS FOR POWER TRAIN ......................................................................................... 81 • HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ............................................................................................ 82 • HYDRAULIC CIRCUIT SCHEMATICS FOR POWER TRAIN ......................................................................................... 83 • HYDRAULIC CIRCUIT DIAGRAM FOR POWER ‘TRAIN ........................................................................................... 84 TORQUE CONVERTER AND TRANSMISSION PIPING ................................................................................................... 85 TRANSMISSION MOUNT.......................................................................................................................... 89 TORQUE CONVERTER OIL COOLER ................................................................................................................ 90 TORQUE CONVERTER OIL FILTER ................................................................................................................ 91 LUBRICATION BYPASS VALVE ................................................................................................................... 92 PILOT OIL FILTER ........................................................................................................................... 93 TORQUE CONVERTER ........................................................................................................................... 94 TORQUE CONVERTER (For cold area) ........................................................................................................... 97 TORQUE CONVERTER REGULATOR VALVE ...........................................................................................................100 TORQUE CONVERTER RELIEF VALVE ..............................................................................................................102 TORQUE CONVERTER RELIEF VALVE (For cold area)...............................................................................................103 TRANSMISSION................................................................................................................................105 TRANSMISSION CONTROL VALVE .................................................................................................................111 • UPPER VALVE ..........................................................................................................................113 • LOWER VALVE ..........................................................................................................................114 • LOWER VALVE (For cold area) ..........................................................................................................115 • MAIN RELIEF VALVE ....................................................................................................................116 • PRIORITY VALVE .......................................................................................................................117 • MODULATING VALVE AND QUICK RETURN VALVE ..............................................................................................118 • REDUCING VALVE .......................................................................................................................120 • ACCUMULATOR VALVE (For cold area).....................................................................................................121 • PILOT REDUCING VALVE..................................................................................................................123 TRANSMISSION SOLENOID VALVE.................................................................................................................124 EMERGENCY MANUAL SPOOL......................................................................................................................127 TRANSFER....................................................................................................................................128 DRIVE SHAFT.................................................................................................................................129 CENTER SUPPORT..............................................................................................................................130 AXLE AND DIFFERENTIAL.......................................................................................................................131 FINAL DRIVE.................................................................................................................................136 TIRE AND WHEEL..............................................................................................................................137 22 TESTING AND ADJUSTING........................................................................................................................138 TABLE OF JUDGEMENT STANDARD VALUE ..........................................................................................................139 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................140 MEASURING ENGINE STALL SPEED ...............................................................................................................141 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION ................................................................................143 MEASURING SHIFT LEVER ......................................................................................................................145 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL .............................................................................................146 TIRE AND WHEEL .............................................................................................................................147 TROUBLESHOOTING.............................................................................................................................148 PRECAUTIONS WHEN TROUBLESHOOTING .......................................................................................................149 METHOD OF READING TROUBLESHOOTING TABLE ................................................................................................151 PREVENTING RECURRENCE OF TROUBLE .......................................................................................................153 METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM ........................................................154 TROUBLESHOOTING TABLE ..................................................................................................................155 1. Machine does not move............................................................................................................155 2. Machine lacks power or speed.....................................................................................................157 3. Excessive time lag when starting machine or shifting gear........................................................................158 4. Torque converter oil temperature too high........................................................................................159 23 DISASSEMBLY AND ASSEMBLY.....................................................................................................................160 HYDRAULIC PUMP..............................................................................................................................161 REMOVAL.................................................................................................................................161 INSTALLATION............................................................................................................................162 TORQUE CONVERTER............................................................................................................................163 REMOVAL.................................................................................................................................163 INSTALLATION............................................................................................................................167 DISASSEMBLY.............................................................................................................................171 ASSEMBLY................................................................................................................................177 TRANSMISSION................................................................................................................................184 REMOVAL.................................................................................................................................184 INSTALLATION............................................................................................................................190 DISASSEMBLY.............................................................................................................................196 ASSEMBLY................................................................................................................................211 TRANSFER....................................................................................................................................227 DISASSEMBLY.............................................................................................................................227 ASSEMBLY................................................................................................................................236 TRANSMISSION CONTROL VALVE..................................................................................................................247 REMOVAL.................................................................................................................................247 INSTALLATION............................................................................................................................248 DISASSEMBLY AND ASSEMBLY................................................................................................................249 FRONT DIFFERENTIAL..........................................................................................................................253 REMOVAL.................................................................................................................................253 INSTALLATION............................................................................................................................255 REAR DIFFERENTIAL...........................................................................................................................257 REMOVAL.................................................................................................................................257 INSTALLATION............................................................................................................................260 DIFFERENTIAL GEAR...........................................................................................................................263 DISASSEMBLY.............................................................................................................................263 ASSEMBLY................................................................................................................................267 FRONT AXLE..................................................................................................................................273 REMOVAL.................................................................................................................................273 INSTALLATION............................................................................................................................275 REAR AXLE...................................................................................................................................277 REMOVAL.................................................................................................................................277 INSTALLATION............................................................................................................................281 CENTER SUPPORT..............................................................................................................................285 REMOVAL.................................................................................................................................285 INSTALLATION............................................................................................................................286 DISASSEMBLY.............................................................................................................................287 ASSEMBLY................................................................................................................................289 DRIVE SHAFT.................................................................................................................................291 DISASSEMBLY.............................................................................................................................291 ASSEMBLY................................................................................................................................293 FINAL DRIVE.................................................................................................................................295 DISASSEMBLY.............................................................................................................................295 ASSEMBLY................................................................................................................................298 24 MAINTENANCE STANDARD.........................................................................................................................301 ENGINE MOUNT ...............................................................................................................................302 TRANSMISSION MOUNT..........................................................................................................................303 TORQUE CONVERTER ...........................................................................................................................304 TORQUE CONVERTER REGULATOR VALVE ...........................................................................................................308 TRANSMISSION ...............................................................................................................................311 TRANSMISSION SOLENOID VALVE ................................................................................................................312 TRANSMISSION CONTROL VALVE .................................................................................................................314 • UPPER VALVE...........................................................................................................................314 • LOWER VALVE...........................................................................................................................316 TRANSFER ...................................................................................................................................318 DRIVE SHAFT ................................................................................................................................320 CENTER SUPPORT .............................................................................................................................321 AXLE MOUNT .................................................................................................................................322 DIFFERENTIAL................................................................................................................................323 FINAL DRIVE ................................................................................................................................327 40 STEERING SYSTEM..................................................................................................................................328 41 STRUCTURE AND FUNCTION.......................................................................................................................328 GENERAL ....................................................................................................................................329 STEERING COLUMN, GEAR BOX AND LINKAGE ......................................................................................................330 HYDRAULIC CIRCUIT FOR STEERING .............................................................................................................331 • HYDRAULIC CIRCUIT SCHEMATICS..........................................................................................................331 • HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................332 STEERING CONTROL SYSTEM ....................................................................................................................333 • STEERING VALVE........................................................................................................................333 • STEERING RELIEF VALVE.................................................................................................................335 • SAFETY VALVE (with suction valve).....................................................................................................336 • OPERATION OF DEMAND SPOOL.............................................................................................................337 • OPERATIONS OF STEERING VALVE..........................................................................................................340 TWO-WAY RESTRICTOR VALVE ...................................................................................................................341 STEERING CYLINDER ..........................................................................................................................342 EMERGENCY STEERING PIPING (If equipped).....................................................................................................343 EMERGENCY STEERING PUMP (If equipped) ......................................................................................................344 DIVERTER VALVE (If equipped) ...............................................................................................................345 42 TESTING AND ADJUSTING........................................................................................................................348 TABLE OF JUDGEMENT STANDARD VALUE ..........................................................................................................349 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................349 MEASURING STEERING WHEEL PLAY ..............................................................................................................350 MEASURING OPERATING FORCE OF STEERING WHEEL ................................................................................................351 MEASURING OPERATING TIME OF STEERING WHEEL .................................................................................................352 TESTING STEERING LINKAGE ...................................................................................................................353 ADJUSTING STEERING LINKAGE .................................................................................................................354 MEASURING STEERING OIL PRESSURE ............................................................................................................356 TROUBLESHOOTING.............................................................................................................................357 TROUBLESHOOTING TABLE ..................................................................................................................358 1. Steering wheel does not turn.....................................................................................................358 2. Steering wheel is sluggish.......................................................................................................359 3. Steering wheel moves unsteadily or is subjected to large shock...................................................................360 4. Machine tends to turn naturally in one particular direction when traveling.......................................................360 5. Left and right turning radii are different.......................................................................................360 43 DISASSEMBLY AND ASSEMBLY.....................................................................................................................361 STEERING GEAR ..............................................................................................................................362 REMOVAL.................................................................................................................................362 INSTALLATION ...........................................................................................................................364 STEERING GEAR BOX ..........................................................................................................................366 DISASSEMBLY.............................................................................................................................366 ASSEMBLY................................................................................................................................367 STEERING VALVE..............................................................................................................................369 REMOVAL.................................................................................................................................369 INSTALLATION............................................................................................................................371 DISASSEMBLY AND ASSEMBLY................................................................................................................373 STEERING CYLINDER...........................................................................................................................375 REMOVAL.................................................................................................................................375 INSTALLATION............................................................................................................................376 DISASSEMBLY.............................................................................................................................378 ASSEMBLY................................................................................................................................380 CENTER HINGE PIN............................................................................................................................382 REMOVAL.................................................................................................................................382 INSTALLATION............................................................................................................................390 44 MAINTENANCE STANDARD.........................................................................................................................400 STEERING COLUMN AND GEAR BOX ...............................................................................................................401 CENTER HINGE PIN ...........................................................................................................................403 STEERING VALVE .............................................................................................................................405 STEERING CYLINDER MOUNT ....................................................................................................................406 STEERING CYLINDER ..........................................................................................................................407 DIVERTER VALVE (If equipped) ...............................................................................................................408 EMERGENCY STEERING PUMP (If equipped) ......................................................................................................409 50 BRAKE AND AIR SYSTEM.............................................................................................................................410 51 STRUCTURE AND FUNCTION.......................................................................................................................410 GENERAL ....................................................................................................................................411 • OUTLINE...............................................................................................................................411 • BRAKE AND AIR CIRCUIT SCHEMATICS......................................................................................................412 • BRAKE AND AIR CIRCUIT DIAGRAM.........................................................................................................413 GENERAL (For cold area).....................................................................................................................413 • OUTLINE...............................................................................................................................413 • BRAKE AND AIR CIRCUIT SCHEMATICS......................................................................................................414 • BRAKE AND AIR CIRCUIT DIAGRAM.........................................................................................................415 AIR GOVERNOR ...............................................................................................................................416 AIR TANK ...................................................................................................................................417 • SAFETY VALVE..........................................................................................................................417 BRAKE VALVE ................................................................................................................................418 • BRAKE ACTUATED........................................................................................................................419 • OPERATING IN BALANCE..................................................................................................................420 • BRAKE RELEASED........................................................................................................................421 TWO-WAY VALVE...............................................................................................................................422 RELAY VALVE.................................................................................................................................423 BRAKE CHAMBER...............................................................................................................................424 SLACK ADJUSTER..............................................................................................................................426 BRAKE.......................................................................................................................................429 PARKING BRAKE...............................................................................................................................431 BRAKE CALIPER...............................................................................................................................433 SPRING CYLINDER.............................................................................................................................434 PARKING BRAKE SOLENOID VALVE................................................................................................................435 52 TESTING AND ADJUSTING........................................................................................................................436 STANDARD VALUE TABLE .......................................................................................................................437 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................438 MEASURING BRAKE PEDAL ......................................................................................................................439 MEASURING AIR PRESSURE .....................................................................................................................440 TESTING BRAKE PERFORMANCE ..................................................................................................................443 CHECKING BRAKE PISTON LEAKAGE ..............................................................................................................444 MEASURING WEAR OF BRAKE DISC ...............................................................................................................445 AIR BLEEDING FROM BRAKE LINE ...............................................................................................................446 TESTING PARKING BRAKE PERFORMANCE ..........................................................................................................447 CHECKING AND ADJUSTING PARKING BRAKE .......................................................................................................448 TROUBLESHOOTING.............................................................................................................................450 TROUBLESHOOTING TABLE ..................................................................................................................451 1. Air pressure does not rise at all................................................................................................451 2. Air pressure does not rise to the specified range................................................................................452 3. Brake is ineffective or not very effective.......................................................................................453 4. Brake does not release, or drags.................................................................................................454 5. Parking brake does not release, or drags.........................................................................................455 53 DISASSEMBLY AND ASSEMBLY.....................................................................................................................456 BRAKE VALVE ................................................................................................................................457 REMOVAL.................................................................................................................................457 INSTALLATION............................................................................................................................459 DISASSEMBLY ............................................................................................................................461 ASSEMBLY ...............................................................................................................................463 BRAKE CHAMBER ..............................................................................................................................465 REMOVAL.................................................................................................................................465 INSTALLATION............................................................................................................................468 DISASSEMBLY.............................................................................................................................471 ASSEMBLY................................................................................................................................474 SLACK ADJUSTER..............................................................................................................................477 REMOVAL.................................................................................................................................477 INSTALLATION............................................................................................................................477 DISASSEMBLY.............................................................................................................................478 ASSEMBLY................................................................................................................................479 BRAKE.......................................................................................................................................480 REMOVAL.................................................................................................................................480 INSTALLATION............................................................................................................................483 DISASSEMBLY.............................................................................................................................486 ASSEMBLY................................................................................................................................489 SPRING CYLINDER.............................................................................................................................492 REMOVAL.................................................................................................................................492 INSTALLATION............................................................................................................................493 DISASSEMBLY.............................................................................................................................494 ASSEMBLY................................................................................................................................495 PARKING BRAKE...............................................................................................................................496 REMOVAL.................................................................................................................................496 INSTALLATION............................................................................................................................499 PARKING BRAKE PAD...........................................................................................................................502 REMOVAL.................................................................................................................................502 INSTALLATION............................................................................................................................502 54 MAINTENANCE STANDARD.........................................................................................................................503 BRAKE VALVE ................................................................................................................................504 BRAKE CHAMBER ..............................................................................................................................506 SLACK ADJUSTER .............................................................................................................................507 BRAKE ......................................................................................................................................508 PARKING BRAKE ..............................................................................................................................510 SPRING CYLINDER ............................................................................................................................511 60 WORK EQUIPMENT SYSTEM............................................................................................................................512 61 STRUCTURE AND FUNCTION.......................................................................................................................512 GENERAL ....................................................................................................................................513 SERIAL NO.: 10001-10161................................................................................................................513 SERIAL NO.: 10162 AND UP................................................................................................................514 WORK EQUIPMENT LEVER LINKAGE ...............................................................................................................515 HYDRAULIC CIRCUIT SYSTEM ...................................................................................................................516 • HYDRAULIC CIRCUIT SCHEMATIC...........................................................................................................516 • HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................517 HYDRAULIC TANK .............................................................................................................................518 • OUTLINE...............................................................................................................................518 • OIL FILTER BYPASS VALVE...............................................................................................................519 • BREATHER..............................................................................................................................519 MAIN CONTROL VALVE .........................................................................................................................520 • RELIEF VALVE..........................................................................................................................522 • SAFETY VALVE (with suction valve).....................................................................................................523 • SUCTION VALVE.........................................................................................................................524 HYDRAULIC CYLINDER .........................................................................................................................525 • LIFT CYLINDER.........................................................................................................................525 • TILT, PITCH CYLINDER..................................................................................................................526 WORK EQUIPMENT .............................................................................................................................527 SERIAL NO.: 10001-10161................................................................................................................527 SERIAL NO.: 10162 AND UP................................................................................................................528 • WORK EQUIPMENT (For cold area)........................................................................................................529 62 TESTING AND ADJUSTING........................................................................................................................531 TABLE OF JUDGEMENT STANDARD VALUE ..........................................................................................................532 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................533 MEASURING PITCH, TILT AND LIFT CONTROL LEVERS ..............................................................................................534 ADJUSTING PITCH, TILT AND LIFT CONTROL LEVERS...............................................................................................535 MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT .............................................................................................536 MEASURING WORK EQUIPMENT SPEED..............................................................................................................537 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT CYLINDER .......................................................................................538 TROUBLESHOOTING.............................................................................................................................539 TROUBLESHOOTING TABLE ..................................................................................................................540 1. Blade does not rise..............................................................................................................540 2. Blade moves slowly or does not have sufficient lifting power.....................................................................541 3. Blade movement becomes slow after it reaches a certain height....................................................................542 4. Blade cannot be held down with lift arm cylinder.................................................................................542 5. Blade has large hydraulic drift..................................................................................................542 6. Blade movement is unsteady during work...........................................................................................542 7. Blade lowers momentarily when control lever is shifted from "Hold" to "Raise"....................................................542 8. Blade does not tilt..............................................................................................................543 9. Blade moves alowly or has insufficient tilt power................................................................................544 10. Excessive hydraulic drift of blade when tilted..................................................................................545 11. Blade does not pitch............................................................................................................545 12. Blade pitch movement is slow or lacks power.....................................................................................545 63 DISASSEMBLY AND ASSEMBLY.....................................................................................................................546 HYDRAULIC TANK..............................................................................................................................547 REMOVAL ................................................................................................................................547 INSTALLATION............................................................................................................................549 HYDRAULIC FILTER............................................................................................................................551 REMOVAL.................................................................................................................................551 INSTALLATION............................................................................................................................552 WORK EQUIPMENT, STEERING PUMP...............................................................................................................553 REMOVAL.................................................................................................................................553 INSTALLATION............................................................................................................................554 SOLENOID VALVE..............................................................................................................................555 REMOVAL ................................................................................................................................555 INSTALLATION............................................................................................................................555 MAIN CONTROL VALVE..........................................................................................................................556 REMOVAL ................................................................................................................................556 INSTALLATION............................................................................................................................557 DISASSEMBLY ............................................................................................................................558 ASSEMBLY................................................................................................................................558 LIFT CYLINDER...............................................................................................................................560 REMOVAL ................................................................................................................................560 INSTALLATION ...........................................................................................................................560 PITCH AND TILT CYLINDER.....................................................................................................................561 REMOVAL.................................................................................................................................561 SERIAL NO.: 10001-10161.............................................................................................................561 SERIAL NO.: 10162 AND UP...........................................................................................................562 INSTALLATION ...........................................................................................................................561 SERIAL NO.: 10001-10161............................................................................................................561 SERIAL NO.: 10162 AND UP...........................................................................................................562 DISASSEMBLY.............................................................................................................................563 ASSEMBLY ...............................................................................................................................565 SERIAL NO.: 10001-10161............................................................................................................565 SERIAL NO.: 10162 AND UP...........................................................................................................568 WORK EQUIPMENT..............................................................................................................................571 REMOVAL.................................................................................................................................571 SERIAL NO.: 10001-10161.............................................................................................................571 SERIAL NO.: 10162 AND UP...........................................................................................................574 INSTALLATION ...........................................................................................................................577 DISASSEMBLY ............................................................................................................................582 SERIAL NO.: 10001-10161............................................................................................................582 SERIAL NO.: 10162 AND UP...........................................................................................................584 ASSEMBLY ...............................................................................................................................586 SERIAL NO.: 10001-10161............................................................................................................586 SERIAL NO.: 10162 AND UP............................................................................................................589 REAR BUMPER.................................................................................................................................592 REMOVAL.................................................................................................................................592 INSTALLATION ...........................................................................................................................594 64 MAINTENANCE STANDARD.........................................................................................................................596 BLADE LINKAGE...............................................................................................................................597 SERIAL NO.: 10001-10161 (1) Blade, frame, support, cylinder yoke.......................................................................597 SERIAL NO.: 10162 AND UP...............................................................................................................598 BLADE LINKAGE (For cold area)...............................................................................................................601 (1) Blade, frame, support, cylinder yoke................................................................................................601 (2) Cutting edge and end bit............................................................................................................604 MAIN CONTROL VALVE .........................................................................................................................605 LIFT CYLINDER ..............................................................................................................................607 TILT, PITCH CYLINDER .......................................................................................................................608 STEERING AND HYDRAULIC PUMP ................................................................................................................610 TORQUE CONVERTER TRANSMISSION AND SWITCH PUMP ..............................................................................................611 80 ELECTRIC AND ELECTRONIC SYSTEM...................................................................................................................612 81 STRUCTURE AND FUNCTION.......................................................................................................................612 ELECTRICAL WIRING DIAGRAM CIRCUIT...........................................................................................................619 ELECTRICAL WIRING DIAGRAM CIRCUIT (For cold area)...........................................................................................619 ENGINE STARTING CIRCUIT ....................................................................................................................624 ENGINE STOP CIRCUIT ........................................................................................................................625 COMBINATION SWITCH .........................................................................................................................626 ELECTRICAL TRANSMISSION CONTROL ............................................................................................................627 • TRANSMISSION CUT-OFF SWITCH...........................................................................................................628 • TRANSMISSION CUT-OFF SELECTOR SWITCH..................................................................................................629 • NEUTRALIZER RELAY.....................................................................................................................630 ELECTRICAL PARKING BRAKE CONTROL ...........................................................................................................631 • PARKING BRAKE VALVE...................................................................................................................633 • PARKING BRAKE RELAY...................................................................................................................633 • PARKING SAFETY RELAY..................................................................................................................633 • NEUTRALIZER RELAY.....................................................................................................................633 • EMERGENCY BRAKE SWITCH................................................................................................................633 1. STARTING SWITCH OFF......................................................................................................................634 2. STARTING SWITCH ON.......................................................................................................................635 AUTO PRIMING SYSTEM (APS)..................................................................................................................640 • OPERATION OF APS......................................................................................................................642 • APS CONTROLLER........................................................................................................................644 • RESISTOR..............................................................................................................................644 • BIMETAL TIMER.........................................................................................................................644 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ................................................................................................645 • OUTLINE...............................................................................................................................645 • MONITOR PANEL.........................................................................................................................645 • WIRING HARNESS........................................................................................................................647 • INDICATION ON MONITOR PANEL...........................................................................................................648 • SENSOR................................................................................................................................650 • BRAKE OIL LEVEL.......................................................................................................................650 • ENGINE OIL LEVEL......................................................................................................................651 • RADIATOR WATER LEVEL..................................................................................................................651 • ENGINE WATER TEMPERATURE, TORQUE CONVERTER OIL TEMPERATURE............................................................................651 • ENGINE OIL PRESSURE...................................................................................................................652 • SPEEDOMETER...........................................................................................................................652 • FUEL LEVEL............................................................................................................................652 • AIR PRESSURE SENSOR...................................................................................................................653 • TRANSMISSION OIL FILTER CLOGGED SENSOR................................................................................................653 • EMERGENCY STEERING OPERATION SENSOR (If equipped).....................................................................................654 • BRAKE LINE FAILURE SENSOR.............................................................................................................654 82 TESTING AND ADJUSTING........................................................................................................................655 ADJUSTING SPEEDOMETER.......................................................................................................................656 TROUBLESHOOTING.............................................................................................................................657 CHECK BEFORE TROUBLESHOOTING............................................................................................................658 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.......................................................................................659 CONNECTOR TERMINAL NUMBERS..............................................................................................................661 PRECAUTION WHEN HANDLING CONNECTOR......................................................................................................665 ELECTRICAL WIRING DIAGRAM...............................................................................................................667 ELECTRICAL CIRCUIT SYSTEM...............................................................................................................668 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 to E-17).................................................................................673 POSITION OF CONNECTOR...............................................................................................................674 E-1. ENGINE DOES NOT START..........................................................................................................682 E-2. ENGINE DOES NOT STOP...........................................................................................................685 E-3. ENGINE STOPS WHEN TRAVELING....................................................................................................685 E-4. a) PARKING BRAKE DOES NOT WORK (PARKING BRAKE SWITCH ON).......................................................................686 b) PARKING BRAKE DOES NOT WORK (AIR PRESSURE LESS THAN 2.0 kg/cm2)..............................................................686 E-5. PARKING BRAKE IS NOT RELEASED..................................................................................................687 E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON.................................................................689 E-7. TRANSMISSION IS NPT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED..........................................................689 E-8. MACHINE DOES NOT TRAVEL FORWARD................................................................................................690 E-9. MACHINE DOES NOT TRAVEL REVERSE................................................................................................692 E-10. TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL).......................................................................694 E-11. MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON. (MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF SELECT....695 E-12. TRANSMISSION CANNOT BE CUT-OFF (WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON AND DEPRESS LEFT BRAKE PEDAL).................695 E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL.......................................................................................696 E-14. PREHEATING DOES NOT DISPLAY...................................................................................................698 a) PREHEATING DOES NOT DISPLAY WHEN TURN PREHEATING SWITCH ON...................................................................698 b) PREHEATING DISPLAYS WHEN TURN PREHEATING SWITCH TURN ON, BUT DOES NOT DISPLAY WHEN TURN PREHEATING SWITCH AUTO...............698 E-15. PREHEATING DISPLAY DOES NOT GO OUT (PREHEATING DISPLAY DOES NOT GO OUT AFTER TURNED PREHEATING SWITCH ON ABOUT 80 SECONDS ....700 E-16. AFTERHEATING DOES NOT DISPLAY.................................................................................................700 E-17. AFTERHEATING DISPLAY DOES NOT GO OUT (AFTERHEATING DISPLAY DOES NOT GO OUT AFTER COOLANT TEMPERATURE BECAME ABOVE 20°C).......700 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 TO M-22)............................................................701 TROUBLESHOOTING TABLE (ELECTRONIC VEHICLE MONITORING SYSTEM)........................................................................703 POSTION OF CONNECTOR................................................................................................................705 M-1. MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON......................................712 a) NO LAMPS ON MONITOR PANEL LIGHT UP...........................................................................................712 b) NO LAMPS ON MONITOR PANEL EXCEPT SPEEDOMETER LAMPS LIGHT UP..................................................................712 c) CAUTION ITEMS DO NOT LIGHT UP................................................................................................712 d) SOME ITEMS DO NOT LIGHT UP...................................................................................................712 M-2. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT..........................................713 M-3. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE STARTING ITEM....713 (a) BRAKE OIL LEVEL FLASHES.....................................................................................................713 (b) ENGINE OIL LEVEL FLASHES....................................................................................................714 (c) COOLANT LEVEL FLASHES.......................................................................................................714 M-4. MACHINE IS NOT BEING OPERATED, BUT PILOT LAMPS LIGHT UP ABNORMALLY.............................................................715 (a) PREHEATING LIGHTS UP........................................................................................................715 (b) TRANSMISSION CUT-OFF LIGHTS UP..............................................................................................715 (c) PARKING BRAKE LIGHTS UP.....................................................................................................716 (d) WORKING LAMP LIGHTS.........................................................................................................716 M-5. WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH.....................................................717 (a) ENGINE OIL PRESSURE SYSTEM..................................................................................................717 (b) ALTERNATOR SYSTEM...........................................................................................................717 M-6. WHEN STARTING SWITCH IS TURNED ON WITH ENGINE STOPPED, CAUTION ITEMS FLASH.....................................................718 (a) ENGINE OIL PRESSURE SYSTEM..................................................................................................718 (b) ALTERNATOR SYSTEM...........................................................................................................718 M-7. WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH...................................................719 (a) AFTER-HEATING FLASHES.......................................................................................................719 (b) CHARGE FLASHES..............................................................................................................719 (c) FUEL LEVEL FLASHES..........................................................................................................719 (d) TRANSMISSION FILTER CLOGGING FLASHES........................................................................................720 (e) EMERGENCY STEERING ACTUATION FLASHES........................................................................................720 (f) BRAKE LINE FAILURE FLASHES..................................................................................................721 (g) ENGINE OIL PRESSURE FLASHES.................................................................................................721 (h) RADIATOR WATER LEVEL FLASHES................................................................................................721 (i) AIR PRESSURE FLASHES........................................................................................................722 (j) ENGINE WATER TEMPERATURE FLASHES............................................................................................722 (k) TRANSMISSION OIL TEMPERATURE FLASHES........................................................................................723 M-8. SPEED DISPLAY STAYS AT “0" AND DOES NOT MOVE...................................................................................724 M-9. HIGH BEAM DOES NOT LIGHT UP. HIGH BEAM LIGHTS UP ABNORMALLY....................................................................725 (a) HIGH BEAM DOES NOT LIGHT UP.................................................................................................725 (b) HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF............................................................................726 (c) HIGH BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO...........................................................726 M-10. TURN SIGNAL INDICATOR DOES NOT FLASH. TURN SIGNAL INDICATOR CONTINUES TO FLASH................................................727 (a) TURN SIGNAL INDICATOR DOES NOT FLASH........................................................................................727 (b) TURN SIGNAL INDICATOR CONTINUES TO FLASH....................................................................................728 M-11. FOR ONE SECOND AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED), ALARM BUZZER DOES NOT SOUND...............................728 M-12. THERE IS NO ABNORMALITY ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS...........................................................729 M-13. FOR TWO SECONDS AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP...........................729 M-14. THERE IS NO ABNORMALITY ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP........................................................730 M-15. WHEN STARTING SIWTCH IS TURNED ON (ENGINE STOPPED), PANEL LIGHTING DOES NOT STAY ON FOR 4 SECONDS.............................731 (a) NONE OF PANEL LAMPS LIGHT UP................................................................................................731 (b) SOME OF PANEL LAMPS DO NOT LIGHT UP.........................................................................................731 M-16. LIGHT SWITCH IS NOT OPERATED, BUT HEAD LAMPS LIGHT UP. HEAD LAMPS STAY ON.....................................................732 M-17. SERVICE METER DOES NOT MOVE...................................................................................................733 M-18. SERVICE METER MOVES WHEN ENGINE IS STOPPED....................................................................................733 M-19. ABNORMALITY IN AIR PRESSURE GAUGE.............................................................................................734 (a) Nothing shown in display area...............................................................................................734 (b) Stays at top level and does not move........................................................................................734 M-20. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.................................................................................735 (a) Nothing shown in display area...............................................................................................735 (b) Stays at bottom position and does not move..................................................................................735 M-21. ABNORMALITY IN TRANSMISSION OIL TEMPERATURE GAUGE.............................................................................736 (a) Nothing shown in display area...............................................................................................736 (b) Stays at bottom position and does not move..................................................................................736 M-22. ABNORMALITY IN FUEL GAUGE.....................................................................................................737 (a) Nothing shown in display area...............................................................................................737 (b) Stays at FULL and does not move.............................................................................................737 TABLE OF MONITOR REFERENCE VALUES...................................................................................................738
DESCRIPTION:
KOMATSU WD600-1 SHOP MANUAL SEBM041E0104 – PDF DOWNLOAD
GENERAL PRECAUTIONS
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5 Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
S.S 29/12/24
