Komatsu WD600 WD600H WD900 Wheel Dozer Workshop Repair Service Manual PDF - MKMTSWD600WD900.zip
A full-service repair guide, complete with Electrical Wiring Diagrams, covering the Komatsu Wheel Dozer models WD600-1, WD600-1H, WD600-3, WD600-6, and WD900-3 — providing every technical detail needed to service, troubleshoot, overhaul, and rebuild these machines the way professional technicians do.
The workshop service and repair manual for the Komatsu Wheel Dozer WD600-1, WD600-1H, WD600-3, WD600-6, and WD900-3 contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,543 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER....1
00 Index and foreword....0
100 Index....3
Composition of shop manual....4
Table of contents....6
200 Foreword and general information....19
Safety notice....20
How to read the shop manual....25
Explanation of terms for maintenance standard....27
Handling of electric equipment and hydraulic component....29
Handling of connectors newly used for engines....38
How to read electric wire code....41
Precautions when carrying out operation....44
Method of disassembling and connecting push-pull type coupler....47
Standard tightening torque table....50
Conversion table....54
01 Specification....0
100 Specification and technical data....61
Specification dimension drawing....62
Specifications....63
Weight table....66
Table of fuel, coolant and lubricants....68
10 Structure, function and maintenance standard....0
100 Engine and cooling system....71
Engine mount and transmission mount....72
Damper....74
Cooling system....76
Cooling fan pump....80
Cooling fan motor....88
201 Power train, Part 1....95
Power train....96
Power train system diagram....97
Torque converter and transmission piping diagram....98
Torque converter....100
Modulation clutch....109
Torque converter regulator valve....110
Transmission....112
Transfer....132
Transmission control valve....134
ECMV....136
Main relief valve and torque converter relief valve....143
Lubrication relief valve....145
202 Power train, Part 2....147
Torque converter oil cooler....148
Torque converter oil filter....149
Drive shaft....151
Center support....154
Axle....156
Differential....160
Limited slip differential....169
Final drive....174
300 Steering system....179
Steering piping diagram....180
Steering column....182
Joystick steering lever linkage....183
Joystick EPC valve....184
Lock valve....185
Steering valve....186
Rotary valve....189
Steering control valve....192
Two-way restrictor valve....208
Stop valve....209
Steering pump....210
Steering cylinder....224
Emergency steering piping diagram....225
Diverter valve....226
Emergency steering pump....234
400 Brake system....237
Brake piping diagram....238
Brake....240
Brake valve....244
Accumulator charge valve....252
EPC relief valve....258
Accumulator (for brake)....260
Slack adjuster....262
Parking brake....266
Parking brake solenoid valve....268
Emergency parking brake release valve....270
Brake cooling pump....271
500 Undercarriage and frame....273
Axle mount....274
Center hinge pin....279
601 Hydraulic system, Part 1....283
Hydraulic piping diagram....284
Work equipment control lever linkage....286
Hydraulic tank....288
Work equipment pump....290
602 Hydraulic system, Part 2....311
Control valve....312
CLSS....326
Functions and operation by valve....330
Accumulator (for PPC circuit)....340
Triple pump....341
700 Work equipment....343
Work equipment linkage....344
Cutting edge and end bit....347
Work equipment lubrication....349
Hydraulic cylinder....352
800 Cab and its attachments....355
ROPS cab....356
Air conditioner....358
901 Electrical system, Part 1....363
Machine monitor system....364
Machine monitor....370
902 Electrical system, Part 2....419
Work equipment control system....420
Transmission controller system....446
903 Electrical system, Part 3....479
Electric transmission control....480
Engine starting/stopping circuit....482
Parking brake circuit....485
Sensor....489
VHMS controller related....509
Electric lever (Work equipment)....515
20 Standard value table....0
100 Standard service value table....519
Standard service value table for engine....520
Standard service value table for chassis....521
30 Testing and adjusting....0
101 Testing and adjusting, Part 1....531
Tools for testing, adjusting, and troubleshooting....533
Sketches of special tools....538
Measuring engine speed....539
Measuring exhaust gas color....541
Measuring exhaust temperature....542
Adjusting valve clearance....544
Testing compression pressures....546
Measuring blow-by pressure....549
Measuring engine oil pressure....550
Testing EGR valve and bypass valve drive oil pressure....551
Measuring intake air (boost) pressure....553
Handling fuel system equipment....554
Releasing residual pressure in fuel system....554
Testing fuel pressures....555
Testing return rate and leakage....556
Bleeding air from fuel circuit....559
Testing leakage in fuel system....561
Handling reduced cylinder mode operation....562
Handling no-injection cranking operation....562
Handling controller voltage circuit....563
Replacing and adjusting alternator and air conditioner compressor belt tension....564
Adjusting modulation clutch speed sensor and speed sensor....565
Measuring directional lever and gear shift lever (Steering wheel specification)....567
Testing and adjusting power train oil pressure....568
Flushing procedure for torque converter and transmission hydraulic circuit....582
Method of moving machine when transmission valve is broken....584
Moving method of machine disabled by short-to-power failure in work equipment potentiometer....586
Adjusting steering stop valve....588
102 Testing and adjusting, Part 2....591
Measuring operating effort of AJSS lever (AJSS specification)....593
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)....594
Testing and adjusting steering stopper bolt (AJSS specification)....596
Testing and adjusting steering wheel (Steering wheel specification)....598
Testing steering oil pressure....600
Bleeding air from steering cylinder circuit....604
Testing hydraulic drive fan....605
Bleeding air from hydraulic drive fan circuit....608
Measuring brake pedal....610
Measuring brake performance....611
Testing and adjusting accumulator charge pressure....612
Testing wheel brake oil pressure....614
Measuring wear of wheel brake disc....616
Bleeding air from wheel brake circuit....617
Releasing residual pressure in brake accumulator circuit....618
Testing parking brake performance....619
Measuring parking brake oil pressure....620
Testing wear of parking brake disc....623
Method of releasing parking brake manually....624
Measuring and adjusting work equipment control lever....625
Measuring work equipment oil pressure....626
Bleeding air from work equipment circuit....631
Moving machine for removing operator cab....632
Preparations for work on troubleshooting of electric system....634
Procedure for testing diodes....638
103 Testing and adjusting, Part 3....641
Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller....642
Special functions of machine monitor (EMMS)....645
104 Testing and adjusting, Part 4....715
VHMS controller initial setting procedure....716
Precautions for replacing VHMS controller....738
Pm-clinic inspection table....744
40 Troubleshooting....0
100 Failure code table and fuse locations....747
Failure codes list....748
Fuse locations....760
200 General information on troubleshooting....763
Points to remember when troubleshooting....764
Sequence of events in troubleshooting....765
Testing before troubleshooting....766
Classification and procedures of troubleshooting....767
Information contained in troubleshooting table....768
Phenomena looking like troubles and troubleshooting Nos....770
Connection table for connector pin numbers....772
T- branch box and T- branch adapter table....808
301 Troubleshooting by failure code (Display of code), Part 1....813
Failure code [1500L0] (TORQFLOW transmission: Double meshing)....814
Failure code [15B0NX] (Transmission filter: Clogged)....816
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)....818
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)....820
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)....822
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)....824
Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON)....826
Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF)....828
Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON)....830
Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF)....832
Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON)....834
Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF)....836
Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON)....838
Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF)....840
Failure code [15W0NT] (Transmission modulation clutch: Overheating)....842
Failure code [2F00MA] (Parking brake: Malfunction)....843
Failure code [2G42ZG] (Front accumulator: Low oil pressure)....846
302 Troubleshooting by failure code (Display of code), Part 2....849
Failure code [2G43ZG] (Rear accumulator: Low oil pressure)....852
Failure code [A000N1] (or VHMS_LED display: ?n2? ? ?01?) (Engine: Overrun)....854
Failure code [AA1ANX] (Air cleaner: Clogging)....856
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)....858
Failure code [AB00MA] (Alternator: Malfunction)....860
Failure code [B@BAZG] (Engine oil pressure: Low error)....862
Failure code [B@BAZK] (Engine oil: Low level)....863
Failure code [B@BCNS] (Engine coolant temperature: Overheating)....864
Failure code [B@BCZK] (Coolant: Low level)....866
Failure code [B@C7NS] (Brake oil: Overheating)....868
Failure code [b@CENS] (Torque converter oil: Overheating)....870
Failure code [B@CENS] (Torque converter oil: Overheating)....872
Failure code [B@GAZK] (Battery electrolyte: Low level)....874
Failure code [B@HANS] (Hydraulic oil: Overheating)....876
Failure code [CA111] (Abnormality in engine controller)....878
Failure code [CA115] (Engine Ne or Bkup speed sensor error)....880
Failure code [CA122] (Charge (boost) pressure sensor high error)....882
Failure code [CA123] (Charge (boost) pressure sensor low error)....884
Failure code [CA131] (Throttle sensor high error)....886
Failure code [CA132] (Throttle sensor low error)....888
Failure code [CA135] (Engine oil pressure sensor high error)....890
Failure code [CA141] (Engine oil pressure sensor low error)....892
Failure code [CA144] (Coolant temperature sensor high error)....894
Failure code [CA145] (Coolant temperature sensor low error)....896
Failure code [CA153] (Charge (boost) temperature sensor high error)....898
Failure code [CA154] (Charge (boost) temperature sensor low error)....900
Failure code [CA187] (Sensor power supply 2 low error)....901
Failure code [CA212] (Engine oil temperature sensor high error)....902
Failure code [CA213] (Engine oil temperature sensor low error)....904
Failure code [CA221] (Atmospheric pressure sensor high error)....906
Failure code [CA222] (Atmospheric pressure sensor low error)....908
Failure code [CA227] (Sensor power supply 2 high error)....910
303 Troubleshooting by failure code (Display of code), Part 3....913
Failure code [CA234] (Engine overspeed)....915
Failure code [CA238] (Ne speed sensor power supply error)....916
Failure code [CA263] (Fuel temperature sensor high error)....918
Failure code [CA265] (Fuel temperature sensor low error)....920
Failure code [CA271] (PCV1 Short circuit)....922
Failure code [CA272] (PCV1 Disconnection)....924
Failure code [CA273] (PCV2 Short circuit)....926
Failure code [CA274] (PCV2 Disconnection)....928
Failure code [CA322] (Injector #1 open/short error)....930
Failure code [CA323] (Injector #5 open/short error)....932
Failure code [CA324] (Injector #3 open/short error)....934
Failure code [CA325] (Injector #6 open/short error)....936
Failure code [CA331] (Injector #2 open/short error)....938
Failure code [CA332] (Injector #4 open/short error)....940
Failure code [CA342] (Calibration code inconsistency)....942
Failure code [CA351] (Injectors drive circuit error)....944
Failure code [CA352] (Sensor power supply 1 low error)....946
Failure code [CA386] (Sensor power supply 1 high error)....948
Failure code [CA431] (Idle validation switch error)....950
Failure code [CA432] (Idle validation action error)....952
Failure code [CA441] (Battery voltage low error)....952
Failure code [CA442] (Battery voltage high error)....953
Failure code [CA449] Common rail pressure high error 2....953
Failure code [CA451] (Common rail pressure sensor high error)....954
Failure code [CA452] (Common rail pressure sensor low error)....956
Failure code [CA553] (Common rail pressure high error 1)....957