Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-08 – PDF DOWNLOAD

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-08 – PDF DOWNLOAD

Language : English
Pages : 2564
Downloadable : Yes
File Type : PDF
Size: 258 MB

TABLE OF CONTENTS:

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-08 – PDF DOWNLOAD

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 21
Important safety notice 21
How to read the shop manual 28
Explanation of terms for maintenance standard 30
Handling equipment of fuel system devices 32
Handling of intake system parts 33
Handling of hydraulic equipment 34
Method of disconnecting and connecting of push-pull type coupler 36
Handling of electrical equipment 39
How to read electric wire code 47
Precautions when performing operation 50
Practical use of KOMTRAX 55
Standard tightening torque table 56
List of abbreviation 62
Conversion table 67
01 Specification 73
Table of contents 74
Specifications 75
Specification drawing 75
Specification 77
Weight table 84
Table of fuel, coolant, and lubricants 86
10 Structure and function 89
Table of contents 90
Engine and cooling system 92
Engine related parts 92
KVGT 94
EGR system piping drawing 100
EGR system circuit diagram 102
EGR valve 103
EGR cooler 105
KCCV layout drawing 107
KCCV ventilator 109
KDPF 111
Engine mount and transmission mount 115
Joint 116
Cooling system 117
Cooling fan pump 121
Cooling fan motor 130
Power train 137
Power train system 137
Drive shaft 140
Power train piping drawing 141
Transmission control 142
Torque converter 144
Torque converter regulator valve 151
Transmission 153
Transfer 170
Transmission control valve 172
Forward and reverse clutch ECMV and gear speed clutch ECMV 175
Lockup clutch ECMV 182
Main relief valve, torque converter relief valve, and main flow selector valve 186
Torque converter oil cooler 191
Center support 192
Lubricating oil relief valve 193
Axle 194
Differential 198
Final drive 208
Steering system 210
Layout of steering parts 210
Steering column 211
Joystick steering lever linkage 212
Steering pump 213
Steering control valve 225
Orbitrol valve 235
Stop valve 241
Emergency steering piping diagram 242
Diverter valve 243
Emergency steering pump 247
Brake system 248
Layout of brake parts 248
Charge valve 250
Brake valve 256
Slack adjuster 261
Accumulator (for brake) 264
Brake 265
Parking brake control 267
Parking brake 268
Parking brake solenoid valve 270
Parking brake emergency release valve 273
Undercarriage and frame 274
Axle mount 274
Center hinge pin 275
Tire 277
Hydraulic system 279
Hydraulic component layout 279
Work equipment control 281
Hydraulic tank 283
Double type gear pump 286
Work equipment pump 287
Control valve 308
CLSS 317
Hydraulic circuit diagram and names of valves 321
Accumulator charge valve 333
Work equipment lock solenoid valve 337
Accumulator (for PPC circuit) 338
Accumulator (for ECSS) 339
Work equipment 340
Work equipment linkage 340
Bucket 341
Bucket positioner and boom positioner 343
Lubrication of work equipment 344
Cab and its attachments 346
ROPS cab 346
Electrical system 347
Engine control system 347
Preheating system 349
Power mode selector circuit 351
Engine output limit function 352
Automatic warm-up function 353
Parking brake control system 354
System operating lamp function 356
Battery disconnect switch function 358
Backup lamp and brake lamp 360
Clearance lamp and headlamp 362
Working lamp 363
Horn circuit 364
Wiper and window washer circuit 365
Transmission controller system 368
Work equipment control system 393
Machine monitor system 413
Rear view monitor system 438
KOMTRAX system 441
System component parts 444
Sensor 478
20 Standard value tables 501
Table of contents 502
Standard service value table 503
Standard value table for engine 503
Standard value table for machine 505
Standard value table for electrical system 520
30 Testing and adjusting 535
Table of contents 536
Related information on testing and adjusting 538
Tools for testing and adjusting 538
Sketch of tools for testing and adjusting 543
Engine and cooling system 545
Testing engine speed 545
Testing boost pressure 547
Testing exhaust gas temperature 549
Testing exhaust gas color 551
Testing and adjusting valve clearance 554
Testing compression pressure 556
Testing blowby pressure 559
Testing engine oil pressure 561
Testing EGR valve and KVGT driving oil pressure 563
Testing fuel pressure 565
Testing fuel return rate and leakage 567
Bleeding air from fuel system 571
Testing fuel circuit for leakage 573
Handling cylinder cutout mode operation 574
Handling no-injection cranking operation 575
Testing of KDPF and muffler stack for looseness and damage 576
Testing of installed condition of cylinder heads and manifolds 577
Testing engine piping for damage and looseness 578
Replacing and adjusting belt for alternator and air conditioner compressor 579
Procedures for cleaning fuel doser 580
Writing compensation values at replacement of injector and engine controller 583
Writing compensation amount for soot accumulation caused by ash on engine controller 587
Power train 590
Adjusting transmission output speed sensor 590
Adjusting transmission input speed sensor 591
Flushing procedure for torque converter and transmission hydraulic circuit 592
Retrieval of disabled machine due to transmission valve failure 594
Testing oil leakage from axle final drive 596
Testing drive shaft for looseness, backlash, and damage 597
Testing and adjusting power train oil pressure 598
Steering system 612
Testing directional lever 612
Testing steering wheel 613
Testing work equipment control lever 615
Testing and adjusting steering circuit oil pressure 617
Bleeding air from steering cylinder circuit 620
Testing and adjusting steering stopper valve 621
Brake system 623
Testing brake pedal 623
Testing and adjusting brake pedal linkage 624
Adjustment procedure of transmission cut-off proximity switch of left brake pedal 625
Testing braking performance 626
Testing and adjusting of brake accumulator charge pressure 627
Testing wheel brake oil pressure 629
Testing lowering of wheel brake pressure 630
Testing wear of wheel brake disc 633
Bleeding air from wheel brake circuit 634
Releasing remaining pressure in brake accumulator circuit 636
Testing parking brake performance 637
Testing parking brake oil pressure 638
Testing wear of parking brake disc 640
Method of releasing parking brake manually 641
Hydraulic system 643
Testing fan speed 643
Testing fan pump circuit oil pressure 644
Bleeding air from hydraulic fan circuit 646
Testing work equipment EPC oil pressure 648
Testing and adjusting work equipment oil pressure 650
Bleeding air from work equipment circuit 656
Releasing remaining pressure from work equipment circuit 657
Testing nitrogen gas pressure in brake accumulator and charging gas 658
Work equipment 665
Testing and adjusting bucket position detection lever 665
Testing and adjusting boom position detection lever 666
Electrical system 667
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 667
Special functions of machine monitor 669
Adjusting rearview camera angle 761
Handling voltage circuit of engine controller 762
Handling battery disconnect switch 763
Testing diodes 764
Pm clinic 765
Pm Clinic service 765
Check sheet 766
40 Troubleshooting 773
Table of contents 774
Related information on troubleshooting 784
Troubleshooting points 784
Sequence of events in troubleshooting 786
Check before troubleshooting 788
Inspection procedure before troubleshooting 790
Preparation work for troubleshooting of electrical system 807
Classification and procedures for troubleshooting 813
Symptom and troubleshooting numbers 816
Information in troubleshooting table 819
Connector list and layout 821
Connector contact identification 836
T-branch box and T-branch adapter table 875
Fuse location table 880
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 883
Precautions when performing troubleshooting of machine monitor 886
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit 888
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 893
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 894
Failure codes table 895
Troubleshooting by failure code (Display of code) 910
Failure code [1500L0] Double Engagement of T/M Clutches 910
Failure code [15B0NX] Transmission Oil Filter Clogging 911
Failure code [15SAL1] Release Trouble of ECMV (Forward) 912
Failure code [15SALH] Malfunction of ECMV (Forward) 914
Failure code [15SBL1] Release Trouble of ECMV (Reverse) 916
Failure code [15SBLH] Malfunction of ECMV (Reverse) 918
Failure code [15SEL1] Release Trouble of ECMV (1st clutch) 920
Failure code [15SELH] Malfunction of ECMV (1st) 922
Failure code [15SFL1] Release Trouble of ECMV (2nd) 924
Failure code [15SFLH] Malfunction of ECMV (2nd) 926
Failure code [15SGL1] Release Trouble of ECMV (3rd) 928
Failure code [15SGLH] Malfunction of ECMV (3rd) 930
Failure code [15SHL1] Release Trouble of ECMV (4th) 932
Failure code [15SHLH] Malfunction of ECMV (4th) 934
Failure code [2F00MA] Failure of Parking Brake Circuit 936
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 939
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 941
Failure code [879AKA] A/C Inner Sensor Open Circuit 943
Failure code [879AKB] A/C Inner Sensor Short Circuit 944
Failure code [879BKA] A/C Outer Sensor Open Circuit 945
Failure code [879BKB] A/C Outer Sensor Short Circuit 946
Failure code [879CKA] Ventilating Sensor Open Circuit 947
Failure code [879CKB] Ventilating Sensor Short Circuit 948
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 949
Failure code [879EMC] Ventilation Damper Abnormality 950
Failure code [879FMC] Air Mix Damper Abnormality 951
Failure code [989A00] Engine Overrun Prevention Activated 952
Failure code [989L00] Engine Controller Lock Caution 1 953
Failure code [989M00] Engine Controller Lock Caution 2 954
Failure code [989N00] Engine Controller Lock Caution 3 955
Failure code [A1U0N3] HC Desorb Request 1 956
Failure code [A1U0N4] HC Desorb Request 2 958
Failure code [AA10NX] Air Cleaner Clogging 960
Failure code [AB00KE] Charge Voltage Low 962
Failure code [AB00KY] Hot Short of Alternator R Terminal 964
Failure code [B@BAZG] Eng Oil Press Low 966
Failure code [B@C7NS] Brake Oil Overheat (Rear) 967
Failure code [B@BCNS] Eng Water Overheat 968
Failure code [B@BCZK] Eng Water Level Low 969
Failure code [B@CENS] T/C Oil Temp Overheat 971
Failure code [B@HANS] HYD Oil Temp Overheat 972
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 973
Failure code [CA122] Chg Air Press Sensor High Error 974
Failure code [CA123] Chg Air Press Sensor Low Error 976
Failure code [CA131] Throttle Sensor High Error 978
Failure code [CA132] Throttle Sensor Low Error 980
Failure code [CA135] Eng Oil Press Sensor High Error 982
Failure code [CA141] Eng Oil Press Sensor Low Error 984
Failure code [CA144] Coolant Temp Sens High Error 986
Failure code [CA145] Coolant Temp Sens Low Error 988
Failure code [CA153] Chg Air Temp Sensor High Error 990
Failure code [CA154] Chg Air Temp Sensor Low Error 992
Failure code [CA187] Sensor 2 Supply Volt Low Error 994
Failure code [CA221] Ambient Press Sens High Error 996
Failure code [CA222] Ambient Press Sens Low Error 998
Failure code [CA227] Sensor 2 Supply Volt High Error 1000
Failure code [CA234] Eng Overspeed 1001
Failure code [CA238] Ne Speed Sensor Supply Volt Error 1002
Failure code [CA239] Ne Speed Sens Supply Volt High Error 1003
Failure code [CA271] IMV/PCV1 Short Error 1004
Failure code [CA272] IMV/PCV1 Open Error 1005
Failure code [CA273] PCV2 Short Error 1006
Failure code [CA274] PCV2 Open Error 1007
Failure code [CA322] Inj #1(L#1) Open/Short Error 1008
Failure code [CA323] Inj #5(L#5) Open/Short Error 1010
Failure code [CA324] Inj #3(L#3) Open/Short Error 1012
Failure code [CA325] Inj #6(L#6) Open/Short Error 1014
Failure code [CA331] Inj #2(L#2) Open/Short Error 1016
Failure code [CA332] Inj #4(L#4) Open/Short Error 1018
Failure code [CA343] ECM Critical Internal Failure 1020
Failure code [CA351] Injectors Drive Circuit Error 1021
Failure code [CA352] Sensor 1 Supply Volt Low Error 1022
Failure code [CA356] Mass Air Flow Sensor High Error 1024
Failure code [CA357] Mass Air Flow Sensor Low Error 1026
Failure code [CA386] Sensor 1 Supply Volt High Error 1028
Failure code [CA431] Idle Validation Sw Error 1029
Failure code [CA432] Idle Validation Process Error 1032
Failure code [CA441] Battery Voltage Low Error 1035
Failure code [CA442] Battery Voltage High Error 1037
Failure code [CA449] Rail Press Very High Error 1038
Failure code [CA451] Rail Press Sensor High Error 1039
Failure code [CA452] Rail Press Sensor Low Error 1041
Failure code [CA515] Rail Press Sens Sup Volt High Error 1043
Failure code [CA516] Rail Press Sens Sup Volt Low Error 1045
Failure code [CA553] Rail Press High Error 1047
Failure code [CA555] Crankcase Press High Error 2 1048
Failure code [CA556] Crankcase Press High Error 3 1049
Failure code [CA559] Rail Press Low Error 1050
Failure code [CA595] Turbo Speed High Error 2 1054
Failure code [CA687] Turbo Speed Low Error 1055
Failure code [CA689] Eng Ne Speed Sensor Error 1057
Failure code [CA691] Intake Air Temp Sens High Error 1059
Failure code [CA692] Intake Air Temp Sens Low Error 1061
Failure code [CA697] ECM Internal Temp Sensor High Error 1063
Failure code [CA698] ECM Int Temp Sensor Low Error 1064
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1065
Failure code [CA778] Eng Bkup Speed Sensor Error 1066
Failure code [CA1117] Persistent Data Lost Error 1068
Failure code [CA1664] KDOC Malfunction 1069
Failure code [CA1691] Regeneration Ineffective 1072
Failure code [CA1695] Sensor 5 Supply Volt High Error 1075
Failure code [CA1696] Sensor 5 Supply Volt Low Error 1077
Failure code [CA1843] Crankcase Press Sens High Error 1079
Failure code [CA1844] Crankcase Press Sens Low Error 1081
Failure code [CA1879] KDPF Delta P Sensor High Error 1083
Failure code [CA1881] KDPF Delta P Sensor Low Error 1085
Failure code [CA1883] KDPF Delta P Sens In Range Error 1087
Failure code [CA1921] KDPF Soot Load High Error 1 1090
Failure code [CA1922] KDPF Soot Load High Error 2 1093
Failure code [CA1923] Dosing Fuel Valve 1 High Error 1098
Failure code [CA1924] Dosing Fuel Valve 1 Low Error 1100
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error 1102
Failure code [CA1927] Dosing Fuel Press Sens High Error 1104
Failure code [CA1928] Dosing Fuel Press Sens Low Error 1106
Failure code [CA1942] Crankcase Press Sens In Range Error 1108
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error 1109
Failure code [CA1977] Fuel Doser Open/Short Error 1112
Failure code [CA1993] KDPF Delta Pressure Low Error 1114
Failure code [CA2185] Throt Sensor Sup Volt High Error 1116
Failure code [CA2186] Throt Sensor Sup Volt Low Error 1118
Failure code [CA2249] Rail Press Very Low Error 1120
Failure code [CA2265] Fuel Feed Pump Open Error 1121
Failure code [CA2266] Fuel Feed Pump Short Error 1123
Failure code [CA2271] EGR Valve Pos Sens High Error 1125
Failure code [CA2272] EGR Valve Pos Sens Low Error 1127
Failure code [CA2349] EGR Valve Solenoid Open Error 1129
Failure code [CA2353] EGR Valve Solenoid Short Error 1131
Failure code [CA2357] EGR Valve Servo Error 1133
Failure code [CA2381] KVGT Pos Sens High Error 1134
Failure code [CA2382] KVGT Pos Sens Low Error 1136
Failure code [CA2383] KVGT Solenoid Open Error 1138
Failure code [CA2386] KVGT Solenoid Short Error 1140
Failure code [CA2387] KVGT Servo Error 1142
Failure code [CA2555] Grid Htr Relay Volt Low Error 1143
Failure code [CA2556] Grid Htr Relay Volt High Error 1145
Failure code [CA2637] KDOC Face Plugging 1147
Failure code [CA2639] Manual Stationary Regeneration Request 1149
Failure code [CA2732] Dosing Fuel Valve 2 High Error 1152
Failure code [CA2733] Dosing Fuel Valve 2 Low Error 1154
Failure code [CA2741] Dosing Fuel Valve Swap Error 1156
Failure code [CA2765] Inj Trim Data Error 1157
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error 1158
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 1161
Failure code [CA3133] KDPF Outlet Press Sens High Error 1166
Failure code [CA3134] KDPF Outlet Press Sens Low Error 1168
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 1170
Failure code [CA3167] Fuel Doser Degradation 1173
Failure code [CA3251] KDOC Inlet Temp High Error 1176
Failure code [CA3253] KDOC Temp Error – Non Regeneration 1179
Failure code [CA3254] KDOC Outlet Temp High Error 1 1182
Failure code [CA3255] KDPF Temp Error – Non Regeneration 1185
Failure code [CA3256] KDPF Outlet Temp High Error 1 1189
Failure code [CA3311] KDOC Outlet Temp High Error 2 1192
Failure code [CA3312] KDPF Outlet Temp High Error 2 1195
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1198
Failure code [CA3314] KDOC Inlet Temp Sens High Error 1201
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 1204
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 1208
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1211
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1214
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1217
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 1220
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1222
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1225
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 1227
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 1229
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output 1231
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 1233
Failure code [D191KA] Disconnection of Neutral Output Relay 1235
Failure code [D191KB] Ground Fault of Neutral Output Relay 1237
Failure code [D191KY] Hot Short of Neutral Output Relay 1239
Failure code [D192KA] Disconnection of ECSS Solenoid 1241
Failure code [D192KB] Ground Fault of ECSS Solenoid 1243
Failure code [D192KY] Hot Short of ECSS Solenoid 1245
Failure code [D193KA] Disconnection of J/S Solenoid Cut Relay 1246
Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay 1248
Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay 1250
Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay 1252
Failure code [D19JKZ] Personal Code Relay Abnormality 1254
Failure code [D1E6KA] Disconnection of Parking Brake Relay 1256
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 1258
Failure code [D1E6KY] Hot Short of Parking Brake Relay 1260
Failure code [D5ZHKA] Failure of Key SW C Signal 1262
Failure code [D5ZHKB] Key SW C Signal Short Circuit 1264
Failure code [D5ZHKZ] Failure of Key SW C Signal 1266
Failure code [D5ZHL6] Disconnection of Key SW C 1268
Failure code [D811MC] KOMTRAX Error 1270
Failure code [D862KA] GPS Antenna Open Circuit 1271
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 1272
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1274
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 1276
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 1277
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 1279
Failure code [DAF0MB] Monitor ROM Abnormality 1280
Failure code [DAF0MC] Monitor Error 1281
Failure code [DAF3KK] Controller Power Source Low (MON) 1282
Failure code [DAF8KB] Camera Power Supply Short Circuit 1284
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 1285
Failure code [DAFGMC] GPS Module Error 1287
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 1288
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 1290
Failure code [DAFQKR] CAN2 Discon (Monitor) 1292
Failure code [DAQ0KK] Controller Power Source Low (T/M) 1293
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 1296
Failure code [DAQ0MC] T/M Con Error 1297
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) 1298
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) 1300
Failure code [DAQ4KB] Ground Fault of Sol Self-Holding Relay 1303
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 1305
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) 1306
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 1308
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 1310
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 1311
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) 1312
Failure code [DAZ9KQ] A/C Model Selection Abnormality 1313
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1314
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1315
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1320
Failure code [DB90KK] Drop in BBC Controller Main Power Source 1325
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) 1328
Failure code [DB90MC] BBC Error 1329
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) 1330
Failure code [DB92KK] Solenoid Power Source Low (BBC) 1332
Failure code [DB95KX] Failure of 5 V Power Source 1 1334
Failure code [DB96KX] Failure of 5 V Power Source 2 1338
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) 1342
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) 1343
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) 1345
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) 1347
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) 1348
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) 1349
Failure code [DBE5KX] Failure of 5V Power Source 1350
Failure code [DBE6KX] Failure of 24 V Power Source 1352
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 1354
Failure code [DDA8KY] Hot Short of Throttle Lock Set SW 1358
Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW 1360
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 1362
Failure code [DDB6L4] Neutral Signal Malfunction 1364
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch 1367
Failure code [DDE5KA] Failure of Emergency Steering Signal 1371
Failure code [DDK3KA] FNR SW Input Signal Disconnection 1373
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 1378
Failure code [DDK4KA] J/S FNR Input Signal Disconnection 1382
Failure code [DDK4KB] J/S FNR Input Signal Short Circuit 1385
Failure code [DDK5L4] Failure of J/S Shift Up/Down SW 1387
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 1389
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 1392
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW 1394
Failure code [DDT0L4] Failure of Shift Mode Select SW 1398
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal 1402
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal 1406
Failure code [DDW9LD] Ground Fault of Kickdown Switch 1410
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW 1414
Failure code [DF10KA] Disconnection of Shift Lever Input 1418
Failure code [DF10KB] Ground Fault of Shift Lever Input 1421
Failure code [DGF1KA] Disconnection of T/M Oil Temp Sensor 1423
Failure code [DGF1KB] Ground Fault of T/M Oil Temp Sensor 1425
Failure code [DGH2KX] Out of Range of HYD Oil Temp Sensor 1427
Failure code [DGR2KB] Ground Fault of Brake Oil Temp Sensor 1429
Failure code [DGR2KZ] Failure of Brake Oil Temp Sensor 1430
Failure code [DGT1KA] Disconnection of T/C Oil Temp Sensor 1432
Failure code [DGT1KB] Ground Fault of T/C Oil Temp Sensor 1434
Failure code [DH21KA] Failure of Loader Pump Press Sensor 1436
Failure code [DH21KB] Loader Pump Press Sensor Short Circuit 1438
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit 1440
Failure code [DHPCKX] Out of Range of Boom Bottom Press Sensor 1442
Failure code [DHPDKX] Out of Range of Boom Head Press Sensor 1444
Failure code [DHQ2KX] Out of Range of Main Flow Sel Valve S 1446
Failure code [DHT1KX] Out of Range of T/M Cut Off Press Sensor 1448
Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit 1450
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor 1451
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor 1454
Failure code [DHT8KA] Failure of Steering Pump Press Sensor 1457
Failure code [DHT8KB] Steering Pump Press Sensor Short Circuit 1459
Failure code [DHT8ZG] Steering Oil Pressure Low 1461
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1462
Failure code [DK55KA] Failure of FNR Lever Potentio 1464
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit 1466
Failure code [DK55L5] Failure of FNR Lever Potentio 1468
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) 1469
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) 1474
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree 1479
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) 1486
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) 1492
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) 1497
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) 1502
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree 1507
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) 1514
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) 1519
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 1524
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 1529
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 1533
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) 1539
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) 1544
Failure code [DK5FKA] Failure of J/S Lever Potentio (Main) 1548
Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main) 1551
Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree 1554
Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub) 1558
Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub) 1561
Failure code [DKA0KA] Failure of Boom Angle Sensor 1564
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 1566
Failure code [DKA0L0] Boom Angle Sensor Dislocation 1568
Failure code [DKA1KA] Failure of Bucket Angle Sensor 1570
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit 1572
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor 1574
Failure code [DLF1LC] Failure of T/M Input Speed Sensor 1576
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1578
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1580
Failure code [DLT3KA] Disconnection of Output Speed Sens (Main) 1582
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) 1584
Failure code [DPQ1KR] LIN Discon (Switch Panel) 1586
Failure code [DPQ2KR] LIN Discon (LED Unit) 1589
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1592
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1595
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator 1597
Failure code [DT22KB] Ground Fault of Work Equip Lock Indic 1601
Failure code [DV00KB] Ground Fault of Buzzer Output 1605
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol 1607
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol 1608
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol 1609
Failure code [DW2BL1] Release Trouble of Main Flow Sel Valve 1610
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve 1611
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) 1612
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) 1614
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) 1616
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) 1618
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) 1620
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) 1622
Failure code [DW4RKA] Disconnection of Bucket EPC Sol (Tilt) 1624
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 1626
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) 1628
Failure code [DW4SKA] Disconnection of Bucket EPC Sol (Dump) 1630
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) 1632
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) 1634
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid 1636
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev Sol 1637
Failure code [DW7BKY] Hot Short of Radiator Fan Rev Sol 1639
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 1640
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid 1642
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 1644
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) 1646
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 1650
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) 1654
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) 1658
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 1662
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) 1666
Failure code [DX16KA] Disconnection of Rad Fan Pump EPC Sol 1670
Failure code [DX16KB] Ground Fault of Rad Fan Pump EPC Sol 1672
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol 1674
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid 1676
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid 1678
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid 1680
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) 1681
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 1683
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) 1685
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 1687
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) 1689
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 1691
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 1693
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) 1695
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 1697
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 1699
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) 1700
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 1702
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 1704
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) 1706
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 1708
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) 1710
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) 1712
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) 1714
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) 1716
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) 1718
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) 1720
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 1722
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 1724
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 1726
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 1728
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 1730
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 1732
Failure code [DXHLKA] Disconnection of J/S Right EPC Solenoid 1734
Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid 1736
Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid 1738
Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid 1740
Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid 1742
Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid 1744
Failure code [LA00L3] Failure of Fan Reverse 1746
Troubleshooting of electrical system (E-mode) 1747
E-1 Engine does not start (Engine does not crank) 1747
E-2 Manual preheating system does not work 1754
E-3 Automatic preheating system does not work 1757
E-4 While preheating is working, preheating monitor does not light up 1759
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 1761
E-6 LCD unit on machine monitor displays nothing 1764
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) 1766
E-8 LCD on machine monitor does not display properly 1768
E-9 Meter unit display on machine monitor is abnormal 1770
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 1773
E-11 Caution LED on machine monitor is abnormal 1776
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly 1778
E-13 Two switches operation of switch panel on machine monitor does not function 1780
E-14 Switch panel buzzer of machine monitor is abnormal 1783
E-15 Rearview monitor does not light up or backlight flickers 1785
E-16 Rearview monitor images are not displayed clearly 1788
E-17 Rearview monitor brightness cannot be adjusted 1791
E-18 Night lighting lamp of rearview monitor is abnormal 1794
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly 1796
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position 1797
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light 1801
E-22 Air cleaner clogging indicator lamp does not light 1803
E-23 Radiator coolant level caution lamp does not light 1804
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light 1806
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light 1808
E-26 Fuel level gauge does not indicate correct level 1809
E-27 Seat belt caution lamp indication is abnormal 1811
E-28 Horn does not sound 1812
E-29 Horn does not stop sounding 1814
E-30 Alarm buzzer does not sound 1815
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 1816
E-32 Kickdown does not work when kickdown switch is turned ON 1817
E-33 The hold switch does not work when it is pressed 1819
E-34 Transmission is always shifted to Neutral, or the brake drags when parking brake applies and FR drive is selected 1821
E-35 Transmission cut-off mode is not selected or not released 1824
E-36 Transmission cut-off setting cannot be released 1826
E-37 FNR switch mode is not selected or not released 1828
E-38 When operating engine mode selector switch, engine mode selector function does not operate properly 1830
E-39 Flow of loader pump does not increase from the minimum rate 1832
E-40 ECSS function cannot be selected or cannot be released 1833
E-41 None of headlamp, clearance lamp, and tail lamp lights 1835
E-42 Clearance lamp and tail lamp do not light up or go out 1837
E-43 Both High and Low beams of headlamp do not light up or go out 1840
E-44 Low beam of headlamp does not light up or go out 1844
E-45 High beam of headlamp does not light up or go out 1846
E-46 Front working lamp does not light up or go out 1848
E-47 Rear working lamp does not light up or go out 1851
E-48 All of turn signal lamps and hazard lamps do not light up or go out 1854
E-49 Turn signal lamps do not light up or go out 1857
E-50 Hazard lamp does not light up or go out 1860
E-51 Brake lamp does not light up or stays lighted 1863
E-52 Backup lamp does not light or continues to light 1866
E-53 Backup buzzer does not sound or continues to sound 1869
E-54 Front wiper does not operate 1871
E-55 Rear wiper does not operate 1874
E-56 Window washer does not operate 1877
E-57 Fuel feed pump does not operate or stop automatically 1880
E-58 KOMTRAX system does not operate properly 1882
Troubleshooting of hydraulic and mechanical system (H-mode) 1884
Information described in troubleshooting table (H-mode) 1884
System chart of hydraulic and mechanical systems 1885
Failure mode and cause table 1889
H-1 Machine does not start 1898
H-2 Torque converter lockup clutch is not disengaged (engine stalls) 1901
H-3 Torque converter lockup clutch is not engaged 1902
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift 1903
H-5 Large shock is made when machine starts or gear is shifted 1906
H-6 Machine starts or gear speed shifts with long time lag 1908
H-7 Torque converter oil temperature is high 1910
H-8 Machine does not turn 1912
H-9 Turning response is poor 1916
H-10 Steering wheel is heavy to turn 1920
H-11 Machine sways or large shocks are made while machine turns 1921
H-12 Turning radius differs between right and left turns 1925
H-13 Wheel brakes do not work or are weak 1926
H-14 Wheel brakes are not released or drag 1928
H-15 Parking brake does not work or it is weak 1929
H-16 Parking brake is not released or drags (including emergency release system) 1930
H-17 Boom does not rise 1931
H-18 Boom moves slow or boom lacks lifting force 1933
H-19 Rising boom slows down at certain height 1935
H-20 Lift cylinders do not serve to hold bucket on ground 1936
H-21 Hydraulic drift of boom is large 1937
H-22 Boom moves up and down during operation 1938
H-23 Bucket does not tilt back 1939
H-24 Bucket moves slow or bucket lacks tilt-back force 1941
H-25 Bucket decelerates during tilt-back operation 1943
H-26 Bucket cylinder does not hold bucket on ground 1944
H-27 Hydraulic drift of bucket is large 1945
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) 1946
H-29 Boom and bucket control levers do not move smoothly and are heavy to move 1947
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall 1948
H-31 Large shocks are made when work equipment starts to move and stops 1949
H-32 When certain work equipment stalls hydraulically, other work equipment moves 1951
H-33 E C S S (travel damper) does not work and machine pitches and bounces 1952
H-34 Fan speed is abnormal (too high or low, or fan does not rotate) 1953
H-35 Unusual noise is heard from around fan 1954
Troubleshooting of engine (S-mode) 1955
Information mentioned in troubleshooting table (S mode) 1955
S-1 When starting switch is turned to START position, engine is not cranked 1956
S-2 The engine cranks but exhaust smoke does not come out 1957
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 1958
S-4 Engine startability is poor 1959
S-5 Engine does not pick-up smoothly 1961
S-6 Engine stops during operation 1963
S-7 Engine runs rough or is unstable 1965
S-8 Engine lacks power 1966
S-9 KDPF gets clogged in a short time 1968
S-10 Engine oil consumption is excessive 1970
S-11 Engine oil becomes contaminated early 1971
S-12 Fuel consumption is excessive 1972
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1973
S-14 Oil pressure drops 1974
S-15 Fuel mixes into engine oil 1975
S-16 Water mixes into engine oil (milky) 1976
S-17 Coolant temperature rises too high (overheating) 1977
S-18 Unusual noise is heard 1978
S-19 Vibration is excessive 1979
S-20 Air cannot be bled from fuel circuit 1980
S-21 Active regeneration is executed frequently 1981
S-22 Active regeneration takes a long time 1982
S-23 White smoke is exhausted during active regeneration 1983
50 Disassembly and assembly 1985
Table of contents 1986
Related information on disassembly and assembly 1988
How to read this manual 1988
Coating materials list 1990
Special tools list 1994
Sketches of special tools 2000
Engine and cooling system 2009
Removal and installation of supply pump assembly 2009
Removal and installation of injector assembly 2015
Removal and installation of cylinder head assembly 2035
Removal and installation of engine hood assembly 2056
Removal and installation of radiator core assembly 2060
Removal and installation of aftercooler 2063
Removal and installation of hydraulic oil cooler 2066
Removal and installation of power train oil cooler assembly 2070
Removal and installation of engine assembly 2072
Removal and installation of engine front oil seal 2079
Removal and installation of engine rear oil seal 2082
Removal and installation of cooling fan and fan motor assembly 2087
Removal and installation of KDPF assembly 2089
Disassembly and assembly of KDPF assembly 2092
Removal and installation of KCCV assembly 2100
Removal and installation of KVGT assembly 2102
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 2106
Removal and installation of air cleaner assembly 2110
Removal and installation of air conditioner compressor assembly 2112
Removal and installation of air conditioner condenser assembly 2114
Removal and installation of belt for alternator and air conditioner compressor 2116
Removal and installation of fuel tank assembly 2118
Power train 2120
Removal and installation of power train unit assembly 2120
Disconnection and connection of power train unit assembly 2125
Disassembly and assembly of input transfer assembly 2129
Disassembly and assembly of torque converter assembly 2135
Disassembly and assembly of transmission assembly 2148
Disassembly and assembly of transfer and parking brake assembly 2175
Removal and installation of front differential assembly 2193
Disassembly and assembly of differential assembly (with LSD) 2195
Disassembly and assembly of differential assembly (without LSD) 2209
Removal and installation of front axle assembly 2220
Removal and installation of rear axle assembly 2222
Disassembly and assembly of final drive assembly (front and rear) 2224
Steering system 2230
Removal and installation of steering valve assembly 2230
Brake system 2232
Removal and installation of brake assembly (front and rear) 2232
Disassembly and assembly of brake assembly (front and rear) 2236
Disassembly and assembly of slack adjuster assembly 2242
Disassembly and assembly of brake accumulator charge valve assembly 2243
Undercarriage and frame 2244
Removal and installation of center hinge pin 2244
Removal and installation of large counterweight assembly 2251
Removal and installation of small counterweight assembly 2253
Hydraulic system 2254
Removal and installation of hydraulic tank assembly 2254
Removal and installation of work equipment pump assembly 2257
Removal and installation of steering and power train pump assembly 2259
Removal and installation of cooling fan pump assembly 2261
Removal and installation of work equipment control valve assembly 2263
Disassembly and assembly of work equipment control valve assembly 2266
Removal and installation of diverter valve assembly 2269
Disassembly and assembly of steering cylinder assembly 2271
Disassembly and assembly of work equipment cylinder assembly 2274
Work equipment 2279
Removal and installation of work equipment assembly 2279
Cab and its attachments 2283
Removal and installation of operator’s cab assembly 2283
Removal and installation of operator’s cab glass (stuck window glass) 2288
Removal and installation of operator’s seat assembly 2296
Removal and installation of seat belt 2298
Removal and installation of air conditioner unit assembly 2299
Electrical system 2304
Removal and installation of machine monitor assembly 2304
Removal and installation of work equipment controller assembly 2305
Removal and installation of rear view monitor assembly 2307
Removal and installation of engine controller assembly 2308
Removal and installation of transmission controller assembly 2310
Removal and installation of monitor controller assembly 2311
Removal and installation of mass air flow and temperature sensor 2313
Removal and installation of KOMTRAX terminal assembly 2314
60 Maintenance standard 2315
Table of contents 2316
Engine and cooling system 2317
Engine mount and transmission mount 2317
Joint 2319
Cooling fan pump 2320
Servo valve 2322
Cooling fan motor 2323
Power train 2325
Drive shaft 2325
Torque converter 2326
Torque converter regulator valve 2330
Transmission 2331
Transmission control valve 2338
Forward and reverse clutch ECMV and gear speed clutch ECMV 2339
Lockup clutch ECMV 2340
Main relief valve, torque converter relief valve, and main flow selector valve 2341
Center support 2343
Lubricating oil relief valve 2344
Axle 2345
Differential 2347
Final drive 2353
Steering system 2355
Steering column 2355
Steering pump 2356
Steering control valve 2360
Steering cylinder 2361
Diverter valve 2363
Emergency steering pump 2364
Brake system 2365
Charge valve 2365
Brake valve 2367
Slack adjuster 2368
Accumulator (for brake) 2369
Brake 2370
Parking brake 2372
Parking brake solenoid valve 2374
Undercarriage and frame 2375
Axle mount 2375
Center hinge pin 2378
Hydraulic system 2380
Hydraulic tank 2380
Double type gear pump 2381
Work equipment pump 2383
Control valve 2385
Accumulator charge valve 2394
Work equipment 2395
Work equipment linkage 2395
Bucket 2398
Bucket positioner and boom positioner 2400
Work equipment cylinder 2401
80 Appendix 2403
Table of contents 2404
Air conditioner components 2405
Precautions for refrigerant 2405
Air conditioner component 2406
Configuration and function of refrigeration cycle 2408
Outline of refrigeration cycle 2409
Air conditioner unit 2411
Dual pressure switch 2416
Air conditioner controller 2417
Compressor 2418
Condenser 2419
Receiver drier 2420
Sunlight sensor 2422
Outer temperature sensor (outside air temperature sensor) 2423
Procedure for testing and troubleshooting 2424
Circuit diagram and arrangement of connector pins 2426
Parts and connectors layout 2429
Testing with self-diagnosis function 2434
Testing temperature control system 2437
Testing vent (mode) changeover 2439
Testing FRESH/RECIRC air changeover 2441
Check evaporator temperature sensor 2443
Testing relays 2445
Troubleshooting chart 1 2447
Troubleshooting chart 2 2448
Information in troubleshooting table 2450
Failure code list related to air conditioner 2451
Failure code [879AKA] A/C Inner Sensor Open Circuit 2452
Failure code [879AKB] A/C Inner Sensor Short Circuit 2454
Failure code [879BKA] A/C Outer Sensor Open Circuit 2456
Failure code [879BKB] A/C Outer Sensor Short Circuit 2458
Failure code [879CKA] Ventilating Sensor Open Circuit 2460
Failure code [879CKB] Ventilating Sensor Short Circuit 2462
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 2464
Failure code [879EMC] Ventilation Damper Abnormality 2466
Failure code [879FMC] Air Mix Damper Abnormality 2469
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 2472
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 2475
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2478
A-4 Troubleshooting for FRESH/RECIRC air changeover 2481
Troubleshooting with gauge pressure 2483
Connection of service tool 2486
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 2488
Handling of compressor oil 2490
90 Diagrams and drawings 2493
Table of contents 2494
Hydraulic circuit diagram 2495
Symbols in hydraulic circuit diagram 2495
Power train hydraulic circuit diagram 2499
Brake hydraulic circuit diagram 2501
Hydraulic circuit diagram 2503
Electric circuit diagram 2507
Symbols in electric circuit diagram 2507
Electrical circuit diagram 2511
Electrical circuit diagram (1/13) 2511
Electrical circuit diagram (2/13) 2513
Electrical circuit diagram (3/13) 2515
Electrical circuit diagram (4/13) 2517
Electrical circuit diagram (5/13) 2519
Electrical circuit diagram (6/13) 2521
Electrical circuit diagram (7/13) 2523
Electrical circuit diagram (8/13) 2525
Electrical circuit diagram (9/13) 2527
Electrical circuit diagram (10/13) 2529
Electrical circuit diagram (11/13) 2531
Electrical circuit diagram (12/13) 2533
Electrical circuit diagram (13/13) 2535
Electrical circuit diagram of floor 2537
Electrical circuit diagram of floor (1/7) (EU specification) 2537
Electrical circuit diagram of floor (2/7) (EU specification) 2539
Electrical circuit diagram of floor (3/7) (EU specification) 2541
Electrical circuit diagram of floor (4/7) (EU specification) 2543
Electrical circuit diagram of floor (5/7) (EU specification) 2545
Electrical circuit diagram of floor (6/7) (EU specification) 2547
Electrical circuit diagram of floor (7/7) (EU specification) 2549
INDEX 2551

DESCRIPTION:

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-08 – PDF DOWNLOAD

SERIAL NUMBERS 10001 and up

Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol markkis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.

Safety points:
• Good arrangement
• Correct work clothes
• Observance of work standard
• Practice of making and checking signals
• Prohibition of operation and handling by
unlicensed workers
• Safety check before starting work
• Wearing protective goggles (for cleaning or
grinding work)
• Wearing shielding goggles and protectors (for
welding work)
• Good physical condition and preparation
• Precautions against work which you are not
used to or you are used to too much

General precautions:

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.• Locate a place in the repair workshop to keep the 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, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.• Only qualified workers must perform the work and operation which require license or qualification.• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.• Before starting work, warm up your body thoroughly to start work under good condition.• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

Preparation:

• Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.• Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them.• When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.• Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of steps when getting on or off the machine.

IMAGES PREVIEW OF THE MANUAL: