Komatsu WA800-3E0, WA900-3E0 Wheel Loader Service Manual
1,590 pages · Publication SEN02034-13
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
What's inside
From the manual's own table of contents: 195 sections, 482 entries. See sample pages (PDF, 829 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
General assembly drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine mount
Transmission mount
Damper
Radiator, oil cooler, aftercooler
Fuel system
Power train
Power train system
Torque converter
Torque converter regulator valve
Show all 195 sections
Transmission
Transfer
Transmission control valve
Torque converter oil cooler
Drive shaft
Center support
Axle
Differential
Final drive
Steering piping
AJSS lever linkage
EPC valve
Steering column
Rotary valve
Steering control valve
Steering unit (orbit-roll valve)48 topics
- Steering pump
- Steering cylinder
- Slow return valve
- Emergency steering piping
- Diverter valve
- Emergency steering pump
- Brake piping
- Brake
- Brake valve
- Accumulator charge valve
- PPC relief valve
- Accumulator (for brake)
- Slack adjuster
- Parking brake
- Parking brake caliper
- Spring cylinder
- Parking brake solenoid
- Brake cooling system (if equipped)
- Brake cooling system (55°C specification) (If equipped)
- Axle mount
- Center hinge pin
- Tire and wheel
- Jack up point
- Hydraulic piping
- Work equipment lever linkage
- Hydraulic tank
- Torque converter charging, PPC and brake pump
- Main control valve
- Accumulator (For PPC valve)
- Main piston pump
- Main piston pump cut-off solenoid valve
- PPC valve
- Switch pump
- Control pump
- Work equipment linkage
- Bucket positioner and lift arm kick-out
- Remote lift arm positioner
- Auto greasing system
- Hydraulic cylinder
- ROPS cab
- Air conditioner
- Machine monitor system
- Main monitor
- Maintenance monitor
- Work equipment control system
- Remote position, joystick steering controller
- Active power maximizing electrical circuit
- Automatic transmission system (ATM)
Engine starting/stopping circuit
Parking brake circuit
Preheating circuit
Emergency engine stop
Hydraulic oil level sensor
Battery and starting motor disconnector switch and starting aid connector
Sensor
Standard value table for engine
Standard value table for chassis
Standard value table for electrical system
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air (boost) pressure
Measuring exhaust gas color
Measuring exhaust temperature
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Testing fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Testing leakage in fuel system
Handling reduced cylinder mode operation
Handling no-injection cranking operation
Handling controller voltage circuit
Adjusting speed sensor
Testing and adjusting alternator belt tension
Testing and adjusting belt tension for air conditioner compressor
Testing and adjusting power train oil pressure
Procedure for operating emergency steering spool when transmission valve fails
Measuring operating effort of AJSS lever (AJSS specification)
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)
Testing and adjusting steering stopper bolt (AJSS specification)
Testing and adjusting steering stop valve
Measuring steering oil pressure
Testing and adjusting emergency steering oil pressure
Bleeding air from steering circuit
Measuring brake pedal
Measuring brake performance
Testing and adjusting accumulator charge pressure
Measuring wheel brake oil pressure reduction
Measuring wear of wheel brake disc
Bleeding air from wheel brake circuit
Releasing residual pressure in brake accumulator circuit
Testing parking brake performance
Measuring parking brake solenoid oil pressure44 topics
- Testing and adjusting wear of parking brake pad
- Testing and adjusting PPC oil pressure
- Adjusting PPC valve linkage
- Testing and adjusting work equipment oil pressure
- Bleeding air from piston pump
- Bleeding air from work equipment circuit
- Adjusting work equipment lever linkage
- Releasing remaining pressure in hydraulic circuit
- Testing and adjusting bucket proximity switch
- Testing and adjusting bucket positioner and tilt limiter
- Testing and adjusting lift arm proximity switch
- Testing and adjusting active working proximity switch
- Checking proximity switch operation pilot lamp
- Testing and adjusting lift arm position detection lever
- Adjusting speedometer module of main monitor
- Special function of engine service monitor
- VHMS controller initial setting procedure
- Precautions for replacing VHMS controller
- Pm-clinic inspection table
- Failure code table
- Method of displaying action code and failure code on machine monitor
- Transmission & AJSS controller LED display
- Transmission control system
- AJSS (Advanced Joystick Steering System) control system
- Location of fuse
- Location of relay
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Testing before troubleshooting
- Classification and procedures of troubleshooting
- Contents of troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Failure code [15B0NX] (Transmission oil filter: Clogging)
- Failure code [AA1ANX] (Air cleaner L.H: Clogged)
- Failure code [AA1BNX] (Air cleaner R.H: Clogged)
- (R terminal signal is present and engine is stopped)
- (Absence of R terminal signal and detection error)
- Failure code [B@BAZK] (Engine oil: Oil level low)
- Failure code [B@BAZG] (Engine oil: Low oil pressure)
- Failure code [B@BCZK] and [b@BCZK] (Radiator coolant: Low coolant level)
- Failure code [B@BDNS] (Engine: Overheating)
- Failure code [B@C6NS] (Front brake oil temperature: Overheating)
- Failure code [B@CENS] (Torque converter oil temperature overheating)
Failure code [B@JFZG] (Brake oil: Low oil pressure)
Failure code [CA111] Engine controller (Left bank): Internal abnormality
Failure code [CB111] Engine controller (Right bank): Internal abnormality5 topics
- Abnormal speed sensor signal
- Excessively high voltage detected
- Excessively low voltage detected
- High voltage detection
- Low voltage detection
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit25 topics
- Failure code [CB271] PCV1 short circuit (Right bank): Short circuit
- Failure code [CA272] PCV1 disconnection (Left bank): Disconnection
- Failure code [CB272] PCV1 disconnection (Right bank): Disconnection
- Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
- Failure code [CB273] PCV2 short circuit (Right bank): Short circuit
- Failure code [CA274] PCV2 disconnection (Left bank): Disconnection
- Failure code [CB274] PCV2 disconnection (Right bank): Disconnection
- short circuit (At left bank): Disconnection, short circuit
- Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch
- Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch
- Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit
- Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality
- Low voltage detection
- High voltage detection
- Failure code [CA431] Trouble in idle validation switch
- Failure code [CA432] Idle validation action error
- Low voltage detection
- High voltage detection
- Abnormally high pressure occurrence
- Excessively high voltage detected
- High voltage detection
- Abnormally low voltage detection
- Excessively high pressure detected
- In-range error
- Loss of pressure feed detected
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal1 topic
- Abnormal phase
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data4 topics
- Bkup signal error
- Communication error
- Distinction error
- Disconnection/Short circuit
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error
Failure code [CA2555] Intake heater relay voltage low error (Left bank only)
Failure code [CA2556] Intake heater relay voltage high error (Left bank only)44 topics
- backup lamp relay system: Disconnection, short circuit or hot short circuit
- Failure code [D180KA] (Preheating relay output system: Disconnection)
- Failure code [D180KB] (Preheating relay output system: Grounding fault)
- Failure code [D180KY] (Preheating relay output system: Hot short circuit)
- joystick caution relay output system: Disconnection or short circuit)
- joystick neutral interlock relay output system: Disconnection or short circuit)
- Failure code [D1EFKA] (Pre-lubrication start relay output system: Disconnection)
- Failure code [D1EFKB] (Pre-lubrication start relay output system: Grounding fault)
- Failure code [D1EFKY] (Pre-lubrication start relay output system: Hot short circuit)
- Failure code [D1EHKA] (Engine start relay output system: Disconnection)
- Failure code [D1EHKB] (Engine start relay output system: Grounding fault)
- Failure code [D1EHKY] (Engine start relay output system: Hot short circuit)
- Failure code [D5ZHL6] (Starting switch terminal C signal: Error)
- Failure code [D5ZSKA] (Machine monitor communication output: Disconnection)
- Failure code [D5ZSKB] (Machine monitor communication output: Grounding fault)
- Failure code [D5ZSKY] (Machine monitor communication output: Hot short circuit)
- Disconnection and grounding fault)
- Low supply voltage)
- Disagreement of model selection signals)
- Low direct supply voltage)
- supply (5 V): Low output voltage)
- supply (24 V): Low output voltage)
- CAN communication abnormality)
- Failure code [DBG2KK] (Solenoid power supply: Low voltage)
- Failure code [DBG3KK] (Battery direct power supply: Low voltage)
- Failure code [DBG9KQ] (Model selection signal: Abnormal)
- Disconnection or grounding fault)
- Failure code [DDE2KB] (Engine oil pressure switch error: Grounding fault)
- Failure code [DDE2L6] (Engine oil pressure switch error: Disconnection or hot short circuit)
- joystick forward-reverse switch system: Disconnection or hot short circuit)
- shifting up/down switch system: Disconnection, short circuit or hot short circuit)
- Disconnection or short circuit)
- Failure code [DGE5KX] (Atmospheric temperature sensor: Out of input signal range (short))
- Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range (short))
- Out of input signal range (short))
- temperature sensor system (Front): Disconnection or short circuit)
- temperature sensor system (Rear): Disconnection or short circuit)
- temperature sensor system (Front): Hot short circuit)
- temperature sensor system (Rear): Hot short circuit)
- temperature sensor system (Front): Disconnection or short circuit)
- temperature sensor system (Rear): Disconnection or short circuit)
- temperature sensor system (front): Hot short circuit)
- Blow-by pressure sensor system: Short circuit)
- Blow-by pressure sensor system: Hot short circuit)
Failure code [DHP2KX] (Main pump oil pressure sensor error: Disconnection or short circuit)2 topics
- sensor system: Out of input signal range)
- Disconnection or short circuit)
Failure code [DHU3KX] (Rear brake oil pressure sensor error: Disconnection or short circuit)5 topics
- steering and frame angle displacement)
- abnormality in steering angle potentiometer system): Disconnection or short circuit)
- abnormality in frame angle potentiometer system: Disconnection or short circuit)
- engine speed sensor system: Disconnection, short circuit or hot short circuit)
- abnormality in speed sensor system: Disconnection, short circuit or hot short circuit)
Failure code [DUM7KY] (Pre-lubrication operation lamp output abnormality: Hot short circuit)58 topics
- Disconnection or grounding fault)
- EPC solenoid system: Disconnection, short circuit or hot short circuit)
- abnormality in 1st solenoid system: Disconnection, short circuit or hot short circuit)
- abnormality in 2nd solenoid system: Disconnection, short circuit or hot short circuit)
- abnormality in 3rd solenoid system: Disconnection, short circuit or hot short circuit)
- abnormality in R solenoid system: Disconnection, short circuit or hot short circuit)
- abnormality in F solenoid system: Disconnection, short circuit or hot short circuit)
- Blow-by pressure sensor system: High pressure error)
- temperature sensor (2): Abnormal rise of exhaust gas temperature)
- temperature sensor (1): Abnormal rise of exhaust gas temperature)
- temperature sensor (2): Abnormal rise of exhaust gas temperature)
- temperature sensor (1): Abnormal rise of exhaust gas temperature)
- Engine does not start
- Abnormality in preheating system
- Transmission and AJSS controller does not work
- Transmission and AJSS controller model selection error
- Parking brake does not work (as the emergency brake)
- Parking brake is applied while machine is traveling
- Parking brake is released as starting switch is turned ON
- operation (parking brake operates normally)
- (when parking brake is not applied)
- Defective kick-down switch
- Defective hold switch
- Lift arm (boom) kick-out is unavailable
- Bucket positioner functional error
- Active working functional error
- Turn signal or hazard display do not flash
- Small lamp does not light up
- Head lamp does not light up
- Abnormality in lighting up of front working lamp
- Abnormality in lighting up of rear working lamp
- Abnormality in transmission cut-off
- Abnormality in low idle selection
- Abnormality in parking brake dragging warning
- Abnormality in buzzer
- Method of using troubleshooting chart
- Machine does not move
- Machine lacks power or speed (every speed range)
- Excessive time lag when starting machine or shifting gear
- Torque converter oil temperature is high
- Steering does not turn
- Turning, response of steering is poor
- Joystick lever is heavy
- Steering wheel shakes or jerks
- Minimum turning radii to right and left are different
- Wheel brakes do not work or braking effect is poor
- Wheel brakes are not released or brakes drag
- Lift arm does not rise
- Lift arm moves slowly or does not have sufficient lifting power
- When raising lift arm, becomes slow at certain height
- Lift arm cylinder cannot hold down bucket
- Lift arm has large amount of hydraulic drift
- Lift arm fluctuates while working
- Lift arm drops momentarily when lever is operated from HOLD to RAISE
- Bucket does not tilt back
- Bucket moves slowly or has insufficient tilt back power
- Bucket movement becomes slow during tilt back
- Bucket cylinder cannot hold down bucket
Bucket has large amount of hydraulic drift
Bucket fluctuates while traveling under load (work equipment valve "HOLD")
Bucket dumps momentarily when lever is operated from HOLD to TILT
Lift arm and bucket levers do not move smoothly
Starting performance is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operations
Engine does not rotate smoothly
Engine lacks output (or lacks power)
Exhaust smoke is black (incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant or fuel)
Coolant temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
Machine monitor system
Machine monitor does not work1 topic
- but all the machine monitors remain lit
Speedometer display does not work
Shift indicator error
Monitor turn signal (hazard) indicator does not light up
Parking indication error
Abnormality in preheating system
Night lamp does not light up
Front work lamp error
Rear work lamp error
Abnormality in transmission cut-off switch
Abnormality in low idle selection
Emergency steering indication error
Parking brake dragging warning error
Buzzer and caution lamp error upon parking brake dragging warning outputting
Buzzer error
Switching state of machine monitor is not stored
Failure indication mode error
Machine monitor does not indicate failure code
Abnormality in auto grease system
Maintenance monitor system
Maintenance monitor does not work1 topic
- the maintenance monitor remains fully lit up
Work check item flashes upon turning starting switch ON (engine not running)
Caution item flashes upon turning starting switch ON (engine running)
The warning buzzer does not sound while caution item indicator flashes
The warning buzzer sounds while monitor indicates no error49 topics
- caution item indicator flashes
- indicates no error
- Night lamp does not light up
- Night lamp remains lit up
- Service meter does not work
- Service meter keeps on working (when engine stops)
- Short circuit, disconnection in dumping solenoid system
- Short circuit in power source at hot end of dumping solenoid
- Short circuit in power source at return end of dumping solenoid
- Boom kick-out function trouble
- Disconnection in boom RAISE, LOWER detection pressure switch
- Short circuit, disconnection in boom angle potentiometer system
- Sensor cannot be adjusted
- Abnormality in engine speed signal system
- Remote positioner RAISE, LOWER LEDs do not light up
- Remote positioner RAISE set LED does not flash
- Remote positioner LOWER set LED does not flash
- Buzzer for switch operation does not sound
- Shock when stopping boom
- Short circuit in boom RAISE, LOWER pressure detection switch
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Removal and installation of engine assembly
- Removal and installation of radiator assembly
- Removal and installation of damper assembly
- Disassembly and assembly of damper assembly
- Removal and installation of fuel tank assembly
- Removal and installation of right bank fuel supply pump assembly
- Removal and installation of left bank fuel supply pump assembly
- Removal and installation of cylinder head assembly
- Removal and installation of fuel injector assembly
- Removal and installation of engine front oil seal
- Removal and installation of engine rear oil seal
- Disassembly and assembly of transfer assembly
- Disassembly and assembly of PTO assembly
- Removal and installation of parking brake calipers assembly
- Disassembly and assembly of parking brake calipers assembly
- Removal and installation of parking brake pad
- Removal and installation of parking brake spring cylinder
- Removal and installation of torque converter and transmission assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of transmission assembly
- Removal and installation of front axle assembly
- Removal and installation of rear axle assembly
- Removal and installation of center support assembly
- Disassembly and assembly of center support assembly
- Removal and installation of differential assembly
Disassembly and assembly of differential assembly
Disassembly and assembly of final drive assembly
Removal and installation of brake assembly
Disassembly and assembly of brake assembly
Removal and installation of left brake valve assembly
Removal and installation of right brake valve assembly
Disassembly and assembly of accumulator charge valve
Disassembly and assembly of slack adjuster
Removal and installation of center hinge pin
Removal and installation of counterweight assembly
Removal and installation of hydraulic tank and filter case assembly
Removal and installation of hydraulic pump assembly
Removal and installation of work equipment control valve assembly
Disassembly and assembly of work equipment control valve assembly
Disassembly and assembly of PPC valve assembly
Removal and installation of steering valve assembly
Removal and installation of diverter valve assembly
Disassembly and assembly of diverter valve assembly
Removal and installation of Orbit-roll assembly
Removal of steering stop valve
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of work equipment assembly
Replacement of boom front bushing
Removal and installation of operator cab assembly
Removal and installation of floor frame assembly
Disassembly and assembly of operator’s seat assembly
Removal and installation of AJSS lever switch assembly
Removal and installation of engine controller assembly
Removal and installation of transmission and steering controller assembly
Removal and installation of main monitor assembly
Removal and installation of air conditioner unit assembly
Power train hydraulic circuit diagram
Brake hydraulic circuit diagram
Work equipment hydraulic circuit diagram
Electrical circuit diagram (1/8)
Electrical circuit diagram (2/8)
Electrical circuit diagram (3/8)
Electrical circuit diagram (4/8)
Electrical circuit diagram (5/8)
Electrical circuit diagram (6/8)
Electrical circuit diagram (7/8)
Electrical circuit diagram (8/8)
Electrical circuit diagram of emergency engine stop
Electrical circuit diagram of hydraulic oil level sensor
Connector arrangement diagram
Inside this manual
Real pages from this service manual (1,590 pages). Open the sample pages (PDF, 829 KB)
- Specifications, page 474: 30 Testing and adjusting
- Diagram, page 642: Related circuit diagram
- Troubleshooting, page 1,122: S-7 Exhaust smoke is black (incomplete combustion)
- Foldout diagram, page 1,574: Electrical circuit diagram (2/8)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the WA800-3E0, WA900-3E0 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual SEN02034-13$159.95
Added to your cart. View cart
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,590 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).