Komatsu Wheel Loader WA500-6R Shop Manual SEN02876-14 – PDF DOWNLOAD

Komatsu Wheel Loader WA500-6R Shop Manual SEN02876-14 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Wheel Loader WA500-6R Shop Manual SEN02876-14 – PDF DOWNLOAD

Language : English
Pages : 1922
Downloadable : Yes
File Type : PDF
Size: 128 MB

TABLE OF CONTENTS:

Komatsu Wheel Loader WA500-6R Shop Manual SEN02876-14 – PDF DOWNLOAD

00 Index and foreword
Index SEN02885-14
Composition of shop manual 2
Table of contents 4
Foreword and general information SEN02886-00
Safety notice 2
How to read the shop manual 7
Explanation of terms for maintenance standard 9
Handling of electric equipment and hydraulic component 11
Handling of connectors newly used for engines 20
How to read electric wire code 23
Precautions when carrying out operation 26
Method of disassembling and connecting push-pull type coupler 29
Standard tightening torque table 32
Conversion table 36
01 Specification
Specification and technical data SEN02887-01
Specification dimension drawing 2
Specifications 3
Weight table 6
Table of fuel, coolant and lubricants 8
10 Structure, function and maintenance standard
Engine and cooling system SEN02888-00
Cooling system 2
Engine mount and transmission mount 5
Power train, Part 1 SEN02889-00
Power train 2
Power train system diagram 3
Joint 5
Drive shaft 6
Power train piping diagram 7
Torque converter 8
Torque converter regulator valve 26
Transmission 28
Transfer 48
Transmission control valve 50
ECMV 54
Main relief valve and torque converter relief valve 61
Lubrication relief valve 63
Power train, Part 2 SEN02890-00
Torque converter oil cooler 2
Torque converter oil filter 3
Center support 6
Axle 8
Differential 10
Limited slip differential 19
Final drive 24
00 Index and foreword SEN02885-14
WA500-6R 5
Steering system SEN02891-01
Steering piping diagram 2
Steering column 3
Steering control valve 4
Steering valve 15
Stop valve 19
Joystick steering lever linkage (if equipped) 20
Steering cylinder 21
Emergency steering piping diagram (if equipped) 24
Diverter valve 25
Brake system SEN02892-02
Brake piping diagram 2
Brake valve 4
Slack adjuster 9
Accumulator charge valve 12
PPC relief valve 16
Accumulator (for brake) 18
Brake 20
Parking brake control 23
Parking brake 24
Parking brake solenoid valve 26
Emergency parking brake release valve 28
Undercarriage and frame SEN02893-00
Axle mount 2
Center hinge pin 7
Hydraulic system, Part 1 SEN02894-00
Hydraulic piping diagram 2
Work equipment control lever linkage 4
Hydraulic tank 5
Cooling fan motor 7
Cooling fan pump 14
Steering pump 21
Work equipment hydraulic pump 32
Hydraulic system, Part 2 SEN02895-00
Control valve 2
CLSS 16
Each function and operation of each valve 21
Accumulator (for PPC circuit) 32
Work equipment electric lever 33
Work equipment SEN02896-01
Work equipment linkage 2
Bucket 6
Bucket positioner and boom kick-out 8
Work equipment lubrication 9
Work equipment cylinder 11
Cab and its attachments SEN02897-00
ROPS cab 2
Air conditioner 4
Electrical system, Part 1 SEN02898-02
Machine monitor system 2
Machine monitor 10
Electrical system, Part 2 SEN02899-00
Work equipment control system 2
Transmission controller system 36
Electrical system, Part 3 SEN02900-00
Electric transmission control 2
Engine starting circuit 6
SEN02885-14 00 Index and foreword
6 WA500-6R
Engine stopping circuit 8
Preheating circuit 9
Parking brake circuit 11
Backup and stop lamp circuits 16
Small lamp and head lamp circuits 18
Working lamp circuit 19
Horn circuit 20
Wiper and window washer circuits 21
Sensor 24
KOMTRAX terminal system (if equipped) 42
20 Standard value table
Standard service value table SEN02926-02
Standard service value table for engine 2
Standard service value table for chassis 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN02927-04
Tools for testing, adjusting, and troubleshooting 3
Measuring engine speed 10
Measuring exhaust gas color 12
Measuring exhaust temperature 14
Adjusting valve clearance 16
Testing compression pressure 17
Measuring blow-by pressure 19
Measuring engine oil pressure 20
Measuring intake air (boost) pressure 21
Handling fuel system equipment 23
Releasing residual pressure in fuel system 23
Testing fuel pressure 24
Testing return rate and leakage 25
Bleeding air from fuel circuit 28
Testing leakage in fuel system 30
Handling reduced cylinder mode operation 31
Handling no injection cranking operation 31
Handling controller voltage circuit 32
Testing and adjusting alternator belt tension 33
Testing and adjusting air conditioner compressor belt tension 34
Adjusting transmission speed sensor 35
Measuring directional lever (Steering wheel specification) 37
Testing and adjusting power train oil pressure 38
Flushing procedure for torque converter and transmission hydraulic circuit 51
Method of moving machine when transmission valve is broken 54
Testing and adjusting, Part 2 SEN02928-04
Testing and adjusting steering stop valve 3
Testing and adjusting steering wheel 5
Testing steering oil pressure 7
Bleeding air from steering cylinder circuit 10
Testing hydraulic drive fan 11
Bleeding air from hydraulic drive fan circuit 14
Measuring brake pedal 16
Measuring brake performance 17
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator 
with nitrogen gas 18
Testing and adjusting accumulator charge pressure 25
Testing wheel brake oil pressure 27
Measuring wear of wheel brake disc 29
00 Index and foreword SEN02885-14
WA500-6R 7
Bleeding air from brake circuit 30
Releasing residual pressure in brake accumulator circuit 32
Testing parking brake performance 33
Measuring parking brake oil pressure 34
Testing wear of parking brake disc 37
Method of releasing parking brake manually 38
Measuring and adjusting work equipment control lever 39
Testing and adjusting work equipment PPC oil pressure 40
Measuring work equipment oil pressure 42
Bleeding air from work equipment circuit 48
Releasing residual pressure in work equipment circuit 49
Method of moving machine when removing operator cab (when splittable cab is used) 50
Testing and adjusting bucket positioner 51
Testing and adjusting lift arm position detecting lever 53
Checking proximity switch operation indication lamp 54
Procedure for testing diodes 55
Preparations for work on troubleshooting of electrical system 56
Testing and adjusting, Part 3 SEN02929-02
Starting KOMTRAX terminal operations 2
Indicator lamps of KOMTRAX terminal 8
Machine monitor-based adjustment at replacement, disassembly and assembly,
and additional installation for each sensor and controller 11
Special functions of machine monitor (EMMS) 13
Testing and adjusting, Part 4 SEN02930-04
Special functions of machine monitor (EMMS) 2
Pm clinic inspection table 40
40 Troubleshooting
Failure codes list and fuse locations SEN02931-02
Failure codes list 2
Fuse locations 13
General information on troubleshooting SEN02932-02
Points to remember when performing troubleshooting 2
How to proceed in troubleshooting 4
Testing before troubleshooting 6
Classification and procedures of troubleshooting 7
Information in troubleshooting table 11
Troubleshooting method for disconnecting wiring harness of pressure sensor system 13
Phenomena looking like troubles and troubleshooting Nos 16
Connection table for connector pin numbers 18
T- branch box and T- branch adapter table 54
Troubleshooting by failure code (Display of code), Part 1 SEN02933-00
Failure code [1500L0] (TORQFLOW transmission : Double meshing) 3
Failure code [15B0NX] (Transmission filter: Clogged) 4
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 6
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 8
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 10
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 12
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 14
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 16
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 18
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 20
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 22
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 24
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 26
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 28
Failure code [2F00MA] (Parking brake: Malfunction) 30
SEN02885-14 00 Index and foreword
8 WA500-6R
Failure code [2G42ZG] (Front accumulator: Low oil pressure) 32
Troubleshooting by failure code (Display of code), Part 2 SEN02934-01
Failure code [2G43ZG] Rear accumulator: Low oil pressure 4
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree 6
Failure code [AA1ANX] Air cleaner: Clogging 10
Failure code [AB00L6] Alternator: Signal disagrees with operating state of engine 12
Failure code [AB00MA] Alternator: Malfunction 14
Failure code [B@BAZG] Low engine oil pressure 16
Failure code [B@BAZK] Engine oil: Low level 18
Failure code [B@BCNS] Coolant: Overheating 20
Failure code [B@BCZK] Coolant: Low level 22
Failure code [b@CENS] Torque converter oil: Overheating 24
Failure code [B@CENS] Torque converter oil: Overheating 25
Failure code [B@GAZK] Battery electrolyte: Low level 26
Failure code [B@HANS] Hydraulic oil: Overheating 27
Failure code [CA111] Abnormality in engine controller 28
Failure code [CA115] Engine Ne or Bkup speed sensor error 31
Failure code [CA122] Charge (boost) pressure sensor high error 32
Failure code [CA123] Charge (boost) pressure sensor low error 34
Failure code [CA131] Throttle sensor high error 36
Failure code [CA132] Throttle sensor low error 39
Failure code [CA135] Engine oil pressure sensor high error 42
Failure code [CA141] Engine oil pressure sensor low error 44
Failure code [CA144] Coolant temperature sensor high error 46
Failure code [CA145] Coolant temperature sensor low error 48
Failure code [CA153] Charge (boost) temperature sensor high error 50
Failure code [CA154] Charge (boost) temperature sensor low error 52
Failure code [CA187] Sensor power supply 2 low error 54
Failure code [CA221] Atmospheric pressure sensor high error 56
Failure code [CA222] Atmospheric pressure sensor low error 58
Failure code [CA227] Sensor power supply 2 high error 60
Troubleshooting by failure code (Display of code), Part 3 SEN02935-01
Failure code [CA234] Engine overspeed 3
Failure code [CA238] Ne speed sensor power supply error 4
Failure code [CA263] Fuel Temp Sensor High Error 6
Failure code [CA265] Fuel Temp Sensor Low Error 8
Failure code [CA271] PCV1 Short circuit 10
Failure code [CA272] PCV1 Disconnection 11
Failure code [CA273] PCV2 Short circuit 12
Failure code [CA274] PCV2 Disconnection 13
Failure code [CA322] Injector #1 open/short error 14
Failure code [CA323] Injector #5 open/short error 16
Failure code [CA324] Injector #3 open/short error 18
Failure code [CA325] Injector #6 open/short error 20
Failure code [CA331] Injector #2 open/short error 22
Failure code [CA332] Injector #4 open/short error 24
Failure code [CA342] Calibration code inconsistency 26
Failure code [CA351] Injectors drive circuit error 27
Failure code [CA352] Sens Supply 1 Volt Low Error 28
Failure code [CA386] Sensor power supply 1 high error 30
Failure code [CA431] Idle validation switch error 31
Failure code [CA432] Idle validation action error 34
Failure code [CA441] Battery voltage low error 36
Failure code [CA442] Battery voltage high error 37
Failure code [CA449] Common rail pressure high error 2 38
Failure code [CA451] Rail Press Sensor High Error 40
Failure code [CA452] Rail Press Sensor Low Error 42
Failure code [CA553] Common rail pressure high error 1 44
00 Index and foreword SEN02885-14
WA500-6R 9
Failure code [CA554] Common rail pressure sensor in range error 45
Failure code [CA559] Supply pump pressure very low error 1 46
Failure code [CA689] Engine Ne speed sensor error 50
Failure code [CA731] Engine Bkup speed sensor phase error 52
Failure code [CA757] All continuous data lost error 53
Failure code [CA778] Engine Bkup speed sensor error 54
Failure code [CA1633] KOMNET datalink timeout error 56
Troubleshooting by failure code (Display of code), Part 4 SEN02936-01
Failure code [CA2185] Throttle sensor supply voltage high error 4
Failure code [CA2186] Throttle sensor power supply low error 6
Failure code [CA2249] Supply pump pressure very low error 2 8
Failure code [CA2555] Intake air heater relay open circuit error 10
Failure code [CA2556] Intake air heater relay short circuit error 12
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit 14
Failure code [D191KA] Joystick steering neutral safety relay: Disconnection 16
Failure code [D191KB] Joystick steering neutral safety relay: Short circuit 18
Failure code [D192KA] ECSS solenoid: Disconnection 20
Failure code [D192KB] ECSS solenoid: Short circuit 21
Failure code [D192KY] ECSS solenoid: Short circuit with power supply line 22
Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection 24
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit 26
Failure code [D193KY] Joystick steering solenoid cut relay: 
Short circuit with power supply line 28
Failure code [D5ZHKA] Terminal C signal: Disconnection 30
Failure code [D5ZHKB] Terminal C signal: Short circuit 34
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit 36
Failure code [D5ZHL6] Terminal C signal: Signal does not match 
engine running or stopped state 38
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree 41
Failure code [DAF3KK] Machine monitor: Low source voltage (input) 44
Failure code [DAF5KP] Machine monitor: Low output voltage 46
Failure code [DAFRKR] CAN communication with machine monitor: 
Communication error (Abnormality in target component system) 48
Failure code [DAQ0KK] Transmission controller: Low source voltage 49
Failure code [DAQ0KT] Transmission controller: Abnormality in controller 52
Failure code [DAQ2KK] Transmission controller load power supply line: 
Low source voltage (input) 53
Failure code [DAQ9KQ] Transmission controller model selection: 
Disagreement of model selection signals 56
Troubleshooting by failure code (Display of code), Part 5 SEN02937-02
Failure code [DAQRKR] CAN communication with transmission controller: 
Communication error (Abnormality in target component system) 3
Failure code [DAQRMA] Transmission controller option setting: Malfunction 8
Failure code [DB2RKR] CAN communication from engine controller: 
Communication error (Abnormality in target component system) 10
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 15
Failure code [DB90KT] Work equipment controller: Abnormality in controller 18
Failure code [DB92KK] Work equipment controller load power supply line: 
Low source voltage (input) 19
Failure code [DB95KX] Work equipment controller power supply output: 
Out of input signal range 22
Failure code [DB99KQ] Work equipment controller model selection: 
Disagreement of model selection signals 24
Failure code [DB9RKR] CAN communication with work equipment controller: 
Communication error (Abnormality in target component system) 25
Failure code [DB9RMA] Work equipment controller option setting: Malfunction 26
Failure code [DB9RMC] CAN communication with work equipment controller: 
Defective operation 27
SEN02885-14 00 Index and foreword
10 WA500-6R
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time 28
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time 30
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time 32
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time 34
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): 
Switch is kept pressed for long time 36
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): 
Switch is kept pressed for long time 38
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time 40
Failure code [DD1FLD] Load meter mode selector switch (A/B): 
Switch is kept pressed for long time 42
Failure code [DD1GLD] Load meter mode selector switch (+/–): 
Switch is kept pressed for long time 44
Failure code [DD1HLD] Load meter display selector switch: 
Switch is kept pressed for long time 46
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree 48
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit 50
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit 53
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree 56
Troubleshooting by failure code (Display of code), Part 6 SEN02938-00
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) 4
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) 6
Failure code [DDK3KA] (Right FNR switch: Disconnection) 8
Failure code [DDK3KB] (Right FNR switch: Short circuit) 10
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 12
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) 14
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) 16
Failure code [DDK6KA] (FNR lever switch: Disconnection) 18
Failure code [DDK6KB] (FNR lever switch: Short circuit) 22
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 24
Failure code [DDT4LD] (Transmission cut-off set switch:
Switch is kept pressed for long time) 26
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 28
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) 30
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) 32
Failure code [DF10KA] (Transmission shift lever switch: Disconnection) 34
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 38
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) 40
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) 42
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 44
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) 46
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) 48
Failure code [DGT1KX] (Torque converter oil temperature sensor:
Out of input signal range) 50
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) 52
Troubleshooting by failure code (Display of code), Part 7 SEN02939-01
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) 4
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor:
Out of input signal range) 6
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) 8
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) 10
Failure code [DHT2L6] (Transmission filter clogging sensor:
Signal disagrees with operating and stopped states of engine) 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 14
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line) 17
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) 20
00 Index and foreword SEN02885-14
WA500-6R 11
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 24
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Short circuit with power supply line) 27
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 30
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):
Short circuit with power supply line) 33
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) 36
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) 40
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Short circuit with power supply line) 43
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main):
Disconnection) 46
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main):
Short circuit with power supply line) 49
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree) 51
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection) 54
Troubleshooting by failure code (Display of code), Part 8 SEN02940-01
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):
Short circuit with power supply line) 4
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) 6
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line) 8
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) 10
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Short circuit with power supply line) 12
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree) 14
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 18
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) 20
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 22
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 24
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) 26
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree) 28
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit) 30
Failure code [DLT4KX] (Transmission output shaft speed sensor:
Out of input signal range) 32
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) 34
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) 36
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 38
Failure code [DV00KB] (Alarm buzzer: Short circuit) 40
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 42
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 43
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 44
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 46
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) 48
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 50
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 52
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) 54
Troubleshooting by failure code (Display of code), Part 9 SEN02941-00
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 10
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) 12
SEN02885-14 00 Index and foreword
12 WA500-6R
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) 14
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) 14
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid:
Short circuit with power supply line) 15
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 16
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 18
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
Short circuit with power supply line) 20
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) 22
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) 24
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Short circuit with power supply line) 26
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) 28
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) 30
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Short circuit with power supply line) 32
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 34
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 36
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid:
Short circuit with power supply line) 38
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 40
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 41
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) 42
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) 43
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) 44
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 45
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 46
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) 48
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 50
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 52
Troubleshooting by failure code (Display of code), Part 10 SEN02942-00
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) 4
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 6
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 8
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) 10
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 12
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 14
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) 16
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 18
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 20
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) 22
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 24
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 26
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) 28
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 30
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 32
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) 34
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) 36
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit) 37
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: 
Short circuit with power supply line) 38
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) 39
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) 40
Failure code [DXHKKY] (3-spool valve retract EPC solenoid:
Short circuit with power supply line) 41
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 42
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 44
00 Index and foreword SEN02885-14
WA500-6R 13
Failure code [DXHLKY] (Joystick steering right EPC solenoid:
Short circuit with power supply line) 46
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) 48
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) 50
Failure code [DXHMKY] (Joystick steering left EPC solenoid:
Short circuit with power supply line) 52
Troubleshooting of electrical system (E-mode) SEN02944-02
Fuse locations 3
Information in troubleshooting table 6
E-1 Engine does not start 7
E-2 Wiper does not operate 12
E-3 Windshield washer does not operate 16
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off 19
E-5 Working lamp does not light up or go off 27
E-6 Turn signal lamp and hazard lamp do not light up or go off 32
E-7 Brake lamp does not light or it keeps lighting up 38
E-8 Backup lamp does not light or it keeps lighting up 40
E-9 Backup buzzer does not sound or it keeps sounding 42
E-10 Horn does not sound or it keeps sounding 44
E-11 Alarm buzzer does not sound or it keeps sounding 47
E-12 Air conditioner does not operate or stop 49
E-13 KOMTRAX system does not work properly 52
E-14 Electric priming pump does not operate or does not stop automatically 54
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02945-00
Method of using troubleshooting chart 3
Table of failure modes and causes 6
H-1 Machine does not start 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)] 12
H-3 Torque converter lockup is not switched ON 
[Machine with lockup clutch (if equipped)] 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is
weak, and gear is not shifted 14
H-5 Shocks are large at the times of starting and shifting gear 16
H-6 Time lag is large at the times of starting and shifting gear 18
H-7 Torque converter oil temperature is high 20
H-8 Steering does not turn 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 22
H-10 Steering response is low 23
H-11 Turning response of steering is poor [machine with joystick steering (if equipped)] 24
H-12 Steering is heavy 25
H-13 When machine turns, it shakes or makes large shocks 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)] 27
H-15 Wheel brake does not work or does not work well 28
H-16 Wheel brake is not released or it drags 29
H-17 Parking brake does not work or does not work well 30
H-18 Parking brake is not released or it drags (including emergency release system) 31
H-19 Lift arm does not rise 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient 33
H-21 When rising, lift arm comes to move slowly at specific height 34
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) 34
H-23 Hydraulic drifts of lift arm occur often 34
H-24 Lift arm wobbles during operation 34
H-25 Bucket does not tilt back 35
H-26 Bucket speed is low or tilting back force is insufficient 36
H-27 Bucket comes to operate slowly in the midst of tilting-back 37
H-28 Bucket cylinder cannot hold down the bucket 37
SEN02885-14 00 Index and foreword
14 WA500-6R
H-29 Hydraulic drifts of bucket occur often 37
H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”) 37
H-31 During operation of machine, engine speed lowers remarkably or engine stalls 38
H-32 Large shocks are made when work equipment starts and stops 38
H-33 When work equipment circuit is relieved singly, other work equipment moves 38
H-34 ECSS does not operate, and pitching and bouncing occur 39
Troubleshooting of engine (S-mode) SEN02946-02
Method of using troubleshooting chart 3
S-1 Engine does not start easily 6
S-2 Engine does not start 7
S-3 Engine does not pick up smoothly 10
S-4 Engine stops during operation 11
S-5 Engine does not rotate smoothly (Engine hunts ) 12
S-6 Engine lacks output (or lacks power) 13
S-7 Exhaust smoke is black (Incomplete combustion) 14
S-8 Oil is consumed much (or exhaust gas color is blue) 15
S-9 Engine oil becomes contaminated quickly 16
S-10 Fuel consumption is excessive 17
S-11 Coolant contains oil (blows back or reduces) 18
S-12 Oil pressure drops 19
S-13 Oil level rises (Water, fuel in oil) 20
S-14 Coolant temperature rises too high (Overheating) 21
S-15 Abnormal noise is made 22
S-16 Vibration is excessive 23
S-17 Air cannot be bled from fuel circuit 24
50 Disassembly and assembly
General information on disassembly and assembly SEN02903-02
How to read this manual 2
Coating materials list 4
Special tool list 7
Sketches of special tools 11
Engine and cooling system (SAA6D140E-5) SEN02904-00
Removal and installation of engine assembly 2
Removal and installation of radiator assembly 7
Removal and installation of air aftercooler 9
Removal and installation of cooling fan and fan motor assembly 10
Removal and installation of radiator guard and cooling fan motor assembly 12
Removal and installation of fuel tank assembly 15
Removal and installation of hood 17
Engine (SAA6D140E-5) SEN02905-02
Removal and installation of fuel supply pump assembly 2
Removal and installation of cylinder head assembly 6
Removal and installation of fuel injector assembly 17
Removal and installation of engine front seal 20
Removal and installation of engine rear seal 24
Power train, Part 1 SEN02906-02
Removal and installation of torque converter and transmission assembly 2
Disconnection and connection of power train unit 8
Disassembly and assembly of input transfer assembly 12
Disassembly and assembly of torque converter assembly (Lockup specification) 19
Disassembly and assembly of torque converter assembly (Lockup-less specification) 32
Power train, Part 2 SEN02907-03
Disassembly and assembly of transmission assembly 2
Disassembly and assembly of transfer and parking brake assembly 32
Removal and installation of front axle assembly 49
Removal and installation of rear axle assembly 51
00 Index and foreword SEN02885-14
WA500-6R 15
Power train, Part 3 SEN02908-02
Removal and installation of front differential assembly 2
Disassembly and assembly of differential assembly (LSD specification) 4
Disassembly and assembly of differential assembly (LSD-less specification) 18
Disassembly and assembly of final drive assembly (Front and rear) 30
Brake system SEN02909-01
Removal and installation of brake assembly (Front and rear) 2
Disassembly and assembly of brake assembly (Front and rear) 6
Disassembly and assembly of slack adjuster assembly 12
Disassembly and assembly of brake accumulator charge valve assembly 13
Undercarriage and frame SEN02910-01
Removal and installation of center hinge pin 2
Removal and installation of large counterweight assembly 9
Removal and installation of small counterweight assembly 10
Hydraulic system SEN02911-01
Removal and installation of hydraulic tank assembly 2
Removal and installation of cooling pump assembly 5
Removal and installation of fan pump assembly 6
Removal and installation of work equipment pump assembly 7
Removal and installation of steering, torque converter charge and EPC pump assembly 9
Removal and installation of work equipment valve assembly 10
Disassembly and assembly of work equipment control valve assembly 13
Disassembly and assembly of steering cylinder assembly 16
Disassembly and assembly of lift arm and bucket cylinder assembly 20
Removal and installation of steering valve assembly 26
Work equipment SEN02912-00
Removal and installation of work equipment assembly 2
Cab and its attachments SEN02913-03
Removal and installation of operator’s cab assembly
(Separate cab and floor specification) 2
Removal and installation of operator’s cab and floor frame assembly
(Cab-floor unit specification) 7
Removal and installation of operator’s cab glass (Stuck glass) 11
Disassembly and assembly of operator’s seat assembly 20
Electrical system SEN02914-00
Removal and installation of engine controller assembly 2
Removal and installation of transmission controller assembly 3
Removal and installation of work equipment controller assembly 4
Removal and installation of air conditioner unit assembly 5
80 Appendix
Air conditioner SEN06712-00
Precautions for refrigerant 3
Troubleshooting procedure 4
Circuit diagram and arrangement of connector pins 6
System diagram 11
Detail of air conditioner unit 13
Parts and connectors layout 15
Testing with self-diagnosis function (indication on control panel) 19
Testing temperature control 22
Testing vent (mode) changeover 23
Testing Fresh/Recirc changeover 25
Testing inside air temp sensor and outside air temp sensor 27
Testing evaporator temperature sensor 29
Testing sunlight sensor 30
Testing relays 31
Troubleshooting chart 1 32
SEN02885-14 00 Index and foreword
16 WA500-6R
Troubleshooting chart 2 33
Information in troubleshooting table 36
Troubleshooting for power supply system (Air conditioner does not operate) 37
Troubleshooting for compressor and refrigerant system (Air is not cooled) 40
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 43
Troubleshooting for temperature control 49
Troubleshooting for vent (mode) changeover 52
Troubleshooting for Fresh/Recirc air changeover 55
Troubleshooting with gauge pressure 57
Connection of service tool 59
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 60
Handling of compressor oil 62
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN02901-03
Power train hydraulic circuit diagram 3
Brake hydraulic circuit diagram 7
Work equipment hydraulic circuit diagram 11
Electrical diagrams and drawings SEN02902-04
Engine electrical circuit diagram 2
Air conditioner electrical circuit diagram 3
Electrical circuit diagram 5
Connector arrangement diagram 19

DESCRIPTION:

Komatsu Wheel Loader WA500-6R Shop Manual SEN02876-14 – PDF DOWNLOAD

SERIAL NUMBERS 60001 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

IMAGES PREVIEW OF THE MANUAL: