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KOMATSU WA50-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:60001 & UP) – PDF DOWNLOAD
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- KOMATSU WA50-6 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:60001 & UP
- PUBLICATION NUMBER:SEN04670-04
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Description
KOMATSU WA50-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:60001 & UP)
KOMATSU WA50-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:60001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA50-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:60001 & UP)
- 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)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts
TABLE OF CONTENTS:
KOMATSU WA50-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:60001 & UP)
COVER............................................................................................................ 1 00 Index and foreword............................................................................................ 0 100 Index.................................................................................................... 3 Composition of shop manual............................................................................... 4 Table of contents........................................................................................ 6 200 Foreword and general information......................................................................... 13 Safety notice............................................................................................ 14 How to read the shop manual.............................................................................. 19 Explanation of terms for maintenance standard............................................................ 21 Handling of electric equipment and hydraulic component................................................... 23 Handling of connectors newly used for engines............................................................ 32 How to read electric wire code........................................................................... 35 Precautions when carrying out operation.................................................................. 38 Method of disassembling and connecting push-pull type coupler............................................ 41 Standard tightening torque table......................................................................... 44 Conversion table......................................................................................... 48 01 Specification................................................................................................. 0 100 Specification and technical data......................................................................... 55 Specification dimension drawing.......................................................................... 56 Specifications........................................................................................... 57 Weight table............................................................................................. 61 Table of fuel, coolant and lubricants.................................................................... 62 10 Structure, function and maintenance standard.................................................................. 0 100 Engine and cooling system................................................................................ 65 Engine mount and transfer mount.......................................................................... 66 Coupling................................................................................................. 68 Cooling system........................................................................................... 69 Cooling system hydraulic piping diagram.................................................................. 70 200 Power train.............................................................................................. 73 Power train.............................................................................................. 75 Power train system diagram............................................................................... 76 Drive shafts............................................................................................. 78 HST hydraulic piping diagram............................................................................. 79 HST pump................................................................................................. 80 HST motor................................................................................................ 90 Transfer.................................................................................................100 Axle.....................................................................................................106 Differential.............................................................................................108 Final drive..............................................................................................113 300 Steering system..........................................................................................119 Steering piping diagram..................................................................................120 Steering column..........................................................................................121 Priority valve...........................................................................................122 Orbit-roll valve.........................................................................................123 Steering cylinder........................................................................................128 400 Brake system.............................................................................................131 Brake control............................................................................................132 Brake (also used as parking brake).......................................................................134 500 Undercarriage and frame..................................................................................137 Axle mount and center hinge pin..........................................................................138 600 Hydraulic system.........................................................................................145 Work equipment hydraulic piping diagram..................................................................146 Work equipment control lever linkage.....................................................................148 Hydraulic tank...........................................................................................149 2-unit gear pump.........................................................................................151 Work equipment control valve.............................................................................152 700 Work equipment...........................................................................................163 Work equipment linkage...................................................................................164 Bucket...................................................................................................167 Bucket positioner........................................................................................168 Work equipment cylinder..................................................................................172 800 Cab and its attachments..................................................................................175 Cab......................................................................................................176 Air conditioner..........................................................................................178 Heater...................................................................................................185 Canopy...................................................................................................187 910 Electrical system, Part 1................................................................................189 Machine monitor system...................................................................................190 Machine monitor..........................................................................................195 HST electronic control system............................................................................199 Electrical system (HST controller system)................................................................200 HST controller...........................................................................................210 920 Electrical system, Part 2................................................................................213 KOMTRAX system...........................................................................................214 Engine start circuit.....................................................................................217 Engine stop circuit......................................................................................218 Preheating circuit.......................................................................................219 Travel mode selector switch..............................................................................220 Travel speed control dial................................................................................221 Sensors..................................................................................................222 20 Standard value table.......................................................................................... 0 100 Standard service value table.............................................................................231 Standard service value table for engine..................................................................232 Standard service value table for chassis.................................................................233 30 Testing and adjusting......................................................................................... 0 110 Testing and adjusting, Part 1............................................................................239 Tools for testing, adjusting, and troubleshooting........................................................240 Testing and adjusting engine speed.......................................................................242 Testing exhaust gas color................................................................................245 Testing and adjusting valve clearance....................................................................246 Testing compression pressure.............................................................................248 Testing engine oil pressure..............................................................................249 Testing and adjusting fuel injection timing..............................................................250 Bleeding air from fuel circuit...........................................................................254 Check of installed condition of cylinder head and manifolds..............................................255 Check of engine piping for damage and looseness..........................................................255 Check of muffler and muffler stack for looseness and damage..............................................256 Check of muffler function................................................................................256 Testing, adjusting and replacing alternator belt.........................................................257 Testing, adjusting and replacing air conditioner compressor belt.........................................258 120 Testing and adjusting, Part 2............................................................................261 Testing operating force of accelerator pedal.............................................................263 Testing fuel level sensor................................................................................265 Testing directional lever................................................................................266 Testing and adjusting HST oil pressure...................................................................267 Adjusting travel speed sensor............................................................................271 Testing and adjusting steering wheel.....................................................................272 Testing and adjusting steering oil pressure..............................................................274 Bleeding air from steering circuit.......................................................................276 Testing brake pedal......................................................................................277 Testing and adjusting brake pedal and linkage............................................................278 Testing and adjusting brake switch.......................................................................279 Testing brake performance................................................................................280 Testing brake disc wear..................................................................................281 Testing and adjusting inching potentiometer linkage......................................................282 Testing and adjusting parking brake control linkage......................................................283 Measuring parking brake performance......................................................................285 Testing and adjusting work equipment control lever.......................................................286 Testing and adjusting work equipment hydraulic pressure..................................................288 Testing travel of main control valve spool...............................................................289 Bleeding air from hydraulic circuit......................................................................290 Releasing remaining pressure in hydraulic circuit........................................................291 Testing and adjusting bucket positioner..................................................................292 Checking proximity switch operation pilot lamp...........................................................293 Procedure for testing diodes.............................................................................294 Preparation work for troubleshooting for electrical system...............................................296 How to start operation of KOMTRAX terminal...............................................................298 Lamp display of KOMTRAX terminal.........................................................................302 Removal and installation of KOMTRAX terminal.............................................................305 Pm clinic inspection chart...............................................................................306 40 Troubleshooting............................................................................................... 0 100 Failure code table and fuse locations....................................................................309 Failure codes table......................................................................................310 How to select failure code display and how to read failure code..........................................311 Fuse locations...........................................................................................314 200 General information on troubleshooting...................................................................319 Points to remember when troubleshooting..................................................................320 Sequence of events in troubleshooting....................................................................321 Testing before troubleshooting...........................................................................322 Classification and procedures of troubleshooting.........................................................323 Information contained in troubleshooting table...........................................................326 Connection table for connector pin numbers...............................................................328 T- branch box and T- branch adapter table................................................................364 300 Troubleshooting by failure code (Display of code)........................................................369 Failure code [12] Directional (FNR) lever: Disconnection, ground fault, hot short........................370 Failure code [13] Engine speed sensor: Disconnection, hot short..........................................374 Failure code [14] Travel speed sensor: Disconnection, ground fault, hot short, defective installation....376 Failure code [22] MB (forward) pressure sensor: Disconnection, ground fault, hot short...................378 Failure code [23] MA (reverse) pressure sensor: Disconnection, ground fault, hot short...................380 Failure code [24] Travel speed variable potentiometer: Disconnection, ground fault, hot short............382 Failure code [25] Inching pedal potentiometer: Disconnection, ground fault, hot short....................384 Failure code [26] HST oil temperature sensor: Ground fault...............................................386 Failure code [32] HST pump forward EPC: Disconnection, short circuit, ground fault, hot short............388 Failure code [33] HST pump reverse EPC: Disconnection, short circuit, ground fault, hot short............390 Failure code [34] HST motor EPC: Disconnection, short circuit, ground fault, hot short...................392 Failure code [36] HST pump forward EPC/reverse EPC: Sticking (foreign matter in system etc.).............394 Failure code [42] HST oil temperature: Overheat..........................................................395 Failure code [52] Source voltage: Voltage drop, disconnection............................................396 Failure code [53] Solenoid power supply: Voltage drop, disconnection.....................................398 Failure code [54] ACC signal: Disconnection, ground fault................................................400 Failure code [55] Potentiometer power supply: Ground fault, hot short....................................402 400 Troubleshooting of electrical system (E-mode)............................................................405 E-1 Engine does not start................................................................................406 E-2 Engine does not stop.................................................................................414 E-3 Preheater does not operate normally..................................................................416 E-4 Travel speed is low or high..........................................................................418 E-5 Parking brake omission alarm malfunctions............................................................420 E-6 Bucket positioner does not function or cannot be reset...............................................422 E-7 Travel direction cannot be changed normally..........................................................424 E-8 Windshield wiper does not operate....................................................................426 E-9 Window washer does not operate.......................................................................430 E-10 Headlamp, clearance lamp, tail lamp and license lamp do not light or go off.........................434 E-11 Working lamp and rotary lamp do not light or go off.................................................440 E-12 Turn signal lamp does not light or go off...........................................................446 E-13 Stop lamp does not light or go off..................................................................450 E-14 Backup lamp does not light or go off................................................................452 E-15 Backup buzzer does not sound or stop sounding.......................................................454 E-16 Horn does not sound or stop sounding................................................................458 E-17 Alarm buzzer does not sound or stop sounding........................................................460 E-18 Fuel level is not displayed normally................................................................462 E-19 Air conditioner does not work.......................................................................464 E-20 KOMTRAX system does not operate normally............................................................474 500 Troubleshooting of hydraulic and mechanical system (H-mode)..............................................479 Method of using troubleshooting chart....................................................................481 Failure phenomenon and cause table.......................................................................484 H-1 The machine does not start...........................................................................486 H-2 The travel speed is slow.............................................................................487 H-3 The traction force is weak...........................................................................488 H-4 Engine stalls when traveling or engine speed drops excessively.......................................489 H-5 Travel speed variable dial does not function.........................................................490 H-6 The steering wheel does not turn.....................................................................491 H-7 The steering wheel is heavy..........................................................................492 H-8 Steering wheel shakes or jerks.......................................................................493 H-9 Machine deviates naturally to one side when traveling................................................493 H-10 The brake does not work or does not work well.......................................................494 H-11 The brake is not released or is dragged.............................................................495 H-12 Parking brake does not work at all or sufficiently..................................................496 H-13 Parking brake is not reset or it drags..............................................................497 H-14 The lift arm does not rise or lower.................................................................498 H-15 The lift arm moves slowly or the lift arm rising force is insufficient..............................499 H-16 When rising, the lift arm comes to move slowly at specific height...................................500 H-17 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).....................500 H-18 Hydraulic drifts of the lift arm occur often........................................................500 H-19 The lift arm wobbles during operation...............................................................500 H-20 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily...........501 H-21 The bucket does not tilt back.......................................................................502 H-22 The bucket moves slowly or the tilting-back force is insufficient...................................503 H-23 The bucket comes to operate slowly in the midst of tilting-back.....................................504 H-24 The bucket cylinder cannot hold down the bucket.....................................................504 H-25 Hydraulic drifts of the bucket occur often..........................................................504 H-26 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)..............504 H-27 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily..............505 H-28 The control levers of the lift arm and bucket do not move smoothly and heavy........................505 600 Troubleshooting of engine (S-mode).......................................................................507 Method of using troubleshooting charts...................................................................509 S-1 Starting performance is poor.........................................................................512 S-2 Engine does not start................................................................................513 S-3 Engine does not pick up smoothly.....................................................................516 S-4 Engine stops during operations.......................................................................517 S-5 Engine does not rotate smoothly......................................................................518 S-6 Engine lacks output (or lacks power).................................................................519 S-7 Exhaust smoke is black (incomplete combustion).......................................................520 S-8 Oil consumption is excessive (or exhaust smoke is blue)..............................................521 S-9 Oil becomes contaminated quickly.....................................................................522 S-10 Fuel consumption is excessive.......................................................................523 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...............................524 S-12 Oil pressure drops..................................................................................525 S-13 Oil level rises (Entry of coolant/fuel).............................................................526 S-14 Coolant temperature becomes too high (overheating)..................................................527 S-15 Abnormal noise is made..............................................................................528 S-16 Vibration is excessive..............................................................................529 50 Disassembly and assembly...................................................................................... 0 100 General information on disassembly and assembly..........................................................531 How to read this manual..................................................................................532 Coating materials list...................................................................................534 Special tools list.......................................................................................537 200 Engine and cooling system................................................................................541 Removal and installation of fuel injection pump assembly.................................................542 Removal and installation of nozzle holder assembly.......................................................547 Removal and installation of cylinder head assembly.......................................................549 Removal and installation of radiator assembly............................................................553 Removal and installation of engine hood assembly.........................................................554 Removal and installation of hydraulic oil cooler assembly................................................555 Removal and installation of radiator and hydraulic oil cooler assembly...................................557 Removal and installation of engine and HST pump assembly.................................................560 Removal and installation of engine front oil seal assembly...............................................564 Removal and installation of engine rear oil seal assembly................................................566 Removal and installation of fuel tank assembly...........................................................567 300 Power train..............................................................................................571 Removal and installation of transfer assembly............................................................572 Disassembly and assembly of transfer assembly............................................................574 Removal and installation of parking brake assembly.......................................................580 Disassembly and assembly of parking brake assembly.......................................................582 Removal and installation of front axle assembly..........................................................585 Removal and installation of rear axle assembly...........................................................586 Disassembly and assembly of axle housing assembly........................................................588 Disassembly and assembly of differential assembly........................................................597 400 Undercarriage and frame..................................................................................609 Removal and installation of center hinge pin.............................................................610 Removal and installation of counterweight assembly.......................................................617 500 Hydraulic system.........................................................................................621 Removal and installation of HST pump assembly............................................................622 Removal and installation of HST motor assembly...........................................................624 Removal and installation of work equipment control valve assembly........................................626 Removal and installation of hydraulic tank assembly......................................................627 Disassembly and assembly of hydraulic cylinder assembly..................................................630 600 Work equipment...........................................................................................635 Removal and installation of work equipment assembly......................................................636 700 Cab and its attachments..................................................................................641 Removal and installation of canopy assembly..............................................................642 Removal and installation of operator’s cab assembly......................................................643 Removal and installation of operator's cab glass (Stuck glass)...........................................648 Removal and installation of floor frame assembly.........................................................656 Removal and installation of heater unit assembly.........................................................661 Removal and installation of air conditioner unit assembly................................................663 Removal and installation of air conditioner condenser assembly...........................................665 Removal and installation of air conditioner compressor assembly..........................................667 800 Electrical system........................................................................................671 Removal and installation of font monitor panel assembly..................................................672 Removal and installation of right side monitor panel assembly............................................674 Removal and installation of HST controller assembly......................................................675 Removal and installation of KOMTRAX terminal assembly....................................................677 90 Diagrams and drawings......................................................................................... 0 100 Hydraulic diagrams and drawings..........................................................................679 Hydraulic circuit diagram................................................................................681 200 Electrical diagrams and drawings.........................................................................684 Electrical circuit diagram (1/2).........................................................................686 Electrical circuit diagram (2/2).........................................................................687 Connector list and stereogram............................................................................688
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
