Komatsu WA500-6 Wheel Loader Shop Manual CEBM022903 PDF

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Komatsu WA500-6 Wheel Loader Shop Manual CEBM022903 – PDF DOWNLOAD

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Komatsu WA500-6 Wheel Loader Shop Manual CEBM022903 – PDF DOWNLOAD 

Language : English
Pages : 2070
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA500-6 Wheel Loader Shop Manual CEBM022903 – PDF DOWNLOAD 

CEBM022903 WA500-6 S/N A93001- 1
CONTENTS 2
00 – FOREWORD 0
GENERAL 23
HOW TO READ THE SHOP MANUAL 24
Volumes 24
Distribution and Updating 24
Filing Method 24
Revised Edition Mark 24
Revisions 24
Symbols 24
HOISTING INSTRUCTIONS 25
Hoisting 25
Making Signs 25
Precautions 25
Precautions for Sling Work 25
Precautions for Using Mobile Crane 26
Precautions for Using Overhead Hoist Crane 26
Selecting Wire Ropes 27
AIR CONDITIONER CIRCUITS 28
Precautions for Handling Hoses and Tubes 28
Disconnecting Hoses and Tubes 28
Connecting Hoses and Tubes 28
MAINTENANCE STANDARD TERMS 29
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT 31
Handling Electric Equipment 31
Handling Wiring Harnesses and Connectors 31
Main Failures Occurring in Wiring Harness 31
Removing, Installing, and Drying Connectors and Wiring Harnesses 32
Handling Controller 36
Troubleshooting Electric Circuits 36
Handling Hydraulic Equipment 37
Handling Connectors Used for Engines 39
Slide Lock Type 39
Pull Lock Type 40
Push Lock Type 40
Turn-housing Type (Round Green Connector) 42
PRECAUTIONS FOR OPERATIONS 43
Precautions when Carrying Out Removal Work 43
Precautions when Carrying Out Installation Work 44
Precautions when Completing the Operation 45
PUSH-PULL COUPLER 46
Type 1 46
Disconnection 46
Connection 46
Type 2 47
Disconnection 47
Connection 47
Type 3 48
Disconnection 48
Connection 48
COATING MATERIALS 49
STANDARD TIGHTENING TORQUE 51
Standard Tightening Torques of Bolts and Nuts 51
Tightening Torques for Split Flange Bolts 52
Tightening Torques for O-Ring Boss Piping Joints 52
Tightening Torques for O-Ring Boss Plugs 53
Tightening Torques for Hoses (Taper Seal Type and Face Seal Type) 53
Tightening Toques for Face Seal Joints 54
For 102, 107, and 114 Engine Series (Bolts and Nuts) 54
For 102, 107, and 114 Engine Series (Eye Joints) 54
For 102, 107, and 114 Engine Series (Taper Screws) 55
ELECTRIC WIRE CODE 56
How to Read Electric Wire Code 56
CONVERSION TABLES 57
Method of Using the Conversion Table 57
SAFETY NOTICE 21
IMPORTANT SAFETY NOTICE 21
General Precautions 21
Preparations for Work 22
Precautions During Work 22
01 – GENERAL 63
SPECIFICATIONS 64
Dimension Drawing 64
Specification Tables 65
WEIGHT TABLE 68
FUEL, COOLANT, AND LUBRICANTS 70
10 – STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 73
ENGINE AND COOLING SYSTEM 79
Cooling System 79
Engine and Transmission Mount 82
Joint 84
Cooling Fan Pump 86
Servo Valve 94
Cooling Fan Motor 98
Hydraulic Motor 102
Suction Valve 103
Reversible Valve 104
Safety Valve 105
POWER TRAIN 106
Drive Line Components 106
Power Train System Diagram 107
Without Lockup Clutch 107
With Lockup Clutch 108
Drive Shaft 110
Power Train Piping Diagram 114
Torque Converter without Lockup Clutch 116
Power Transmission Route 122
Oil Flow 123
Torque Converter with Lockup Clutch 124
Power Transmission Route: Lockup Clutch Disengaged 131
Power Transmission Route: Lockup Clutch Engaged 132
Oil Flow 133
Torque Converter Regulator Valve 134
Transmission with Lockup Clutch 136
Disc Clutch 150
Power Transmission Route 152
Transfer 162
Transmission Control Valve (without Lockup Clutch) 164
Transmission Control Value (with Lockup Clutch) 168
ECMV (Electronic Control Modulation Valve) 172
Pressure Control Valve and Fill Switch 173
Operation of ECMV 174
For Lockup Clutch 177
Main Relief Valve and Torque Converter Relief Valve 180
Outline 182
Operation 182
Lubrication Relief Valve 184
Torque Converter Oil Cooler 186
Torque Converter Oil Filter 188
Center Support 190
Axle 194
Front Axle 194
Rear Axle 196
Differential 198
Front Differential 198
Front Differential (with Limited Slip Differential) 199
Rear Differential 200
Rear Differential (with Limited Slip Differential) 201
Limited Slip Differential (if equipped) 207
Final Drive 213
STEERING SYSTEM 217
Steering Piping Diagram 217
Steering Column 218
Steering Control Valve 220
Steering Relief Valve 227
Safety Suction Valve 229
Steering Valve 231
Stop Valve 236
Joystick Steering Lever Linkage (if equipped) 237
Steering Cylinder 238
Emergency Steering (if equipped) 241
Piping Diagram 241
Diverter Valve (for emergency steering) 242
Operation 246
BRAKE SYSTEM 248
Piping Diagram 248
Brake Valve 250
Slack Adjuster 256
Accumulator Charge Valve 259
PPC Relief Valve 263
Accumulator (for Brake) 265
Brake 266
Parking Brake Control 270
Parking Brake 272
Parking Brake Solenoid Valve 274
Emergency Parking Brake Release Valve 276
UNDERCARRIAGE AND FRAME 278
Axle Mount 278
Center Hinge Pin 282
HYDRAULIC SYSTEM 286
Hydraulic Piping Diagram 286
Work Equipment Control Lever Linkage 288
Hydraulic Tank 289
Steering Pump 292
Pump Unit 294
Servo Valve 299
LS Valve 302
CO Valve 302
Work Equipment Hydraulic Pump HPV190 304
LS Valve 311
PC Valve 317
PC-EPC Valve 324
Control Valve 328
CLSS (Closed Center Load-Sensing System) 342
Function and Operation of Each Valve 348
Pressure Compensation Valve 348
LS Shuttle Valve 354
LS Bypass Valve 356
ECSS Control Valve 358
Accumulator Pressure Relief Valve 360
Accumulator Charge Valve 362
Accumulator (for PPC Circuit) 367
Work Equipment Electric Lever 368
WORK EQUIPMENT 374
Work Equipment Linkage 374
Bucket 378
Bucket 5 6 M3 (with Bolt-On Cutting Edge) 378
Bucket 5 2 M3 (with Teeth and Segment Edge) 379
Bucket Positioner and Boom Kickout 380
Work Equipment Lubrication 381
CAB AND ITS ATTACHMENTS 383
ROPS Cab 383
Air Conditioner 385
Air Conditioner Piping Diagram 385
Cooling Circuit Diagram 386
Air Conditioner Unit 387
Condenser 388
Receiver 390
Air Conditioner Panel 391
ELECTRICAL SYSTEM 394
Machine Monitor System 394
Machine Monitor Circuits 396
Machine Monitor 402
Machine Monitor Operation Switches 404
Items Displayed on Monitor 405
Character Display Function 415
Operator Mode Functions 416
Service Mode Functions 419
Service Mode Menu 420
Electrical System Failure History Display Function 424
Mechanical System Failure History Display Function 426
Real-Time Monitor Function 427
Engine Reduced-Cylinder (Cylinder Cut-out) Function 433
No Injection Cranking Function 434
Adjustment Function 435
Maintenance Monitoring Function 437
Operating Information Display Function 441
Optional Device Selecting Function 443
Machine Serial Number Input Function 443
Model Selection Function 443
Load Meter Function (if equipped) 444
Rear Side of Machine Monitor 451
Connector Signal Tables 453
Work Equipment Control System 461
Work Equipment Controller 461
Work Equipment Controls 463
Remote Positioner 471
Lift Arm Positioner 473
Semi-Automatic Digging 478
Pump Swash Plate Control 481
Joystick Steering Control 484
Real-Time Monitor 486
Diagnosis 491
Input and Output Signals 492
Transmission Controller System 495
Electrical Circuit Diagram 495
Transmission Controller Gearshifting Control 497
Auto-Shift Points Table 501
Transmission Controller Protection Function 502
Engine Control 505
Transmission Cutoff Control 508
ECSS Function 510
Economy Lamp 512
Cooling Fan Control 513
Right FNR Switch Control (if equipped) 517
Joystick Control 519
Real-Time Monitor 522
Diagnosis 530
Input and Output Signals 531
ELECTRONIC TRANSMISSION CONTROL 534
Combination Switch 536
Engine Starting Circuit 538
Engine Stopping Circuit 540
Preheating Circuit 541
Parking Brake Circuit 543
Backup and Stop Lamp circuit 548
Small Lamp and Head Lamp Circuits 550
Working Lamp Circuit 551
Horn Circuit 552
Wiper and Window Washer Circuits 553
Sensors and Switches 556
Input Shaft Speed Sensor 556
Output Shaft Speed Sensor 556
Left Brake Pressure Sensor 557
Transmission Oil Temperature Sensor 558
Torque Converter Oil Temperature Sensor 558
Hydraulic Oil Temperature Sensor 558
Axle Oil Temperature Sensor 558
Kickdown Hold Switch 559
Joystick Knob (if equipped) 560
Right FNR Switch (if equipped) 561
Lift Arm Angle Sensor (if equipped) 562
Loader Pump Pressure Sensor 563
Lift Arm Cylinder Bottom Pressure Sensor 563
Lift Arm Cylinder Head Pressure Sensor (Load Meter) (if equipped) 563
Fuel Level Sensor 565
Parking Brake Pressure Switch 566
Stop Lamp Pressure Switch 566
Air Cleaner Clogging Sensor 567
Transmission Clogging Sensor 568
Steering Oil Pressure Sensor Switch 569
Radiator Coolant Level Sensor 570
Brake Accumulator Pressure Switch (front and rear) 571
Battery Electrolyte Level Sensor 572
Accelerator Pedal Sensor 573
Emergency Brake Pressure Switch (front) 574
Emergency Brake Pressure Switch (rear) 574
KOMTRAX SYSTEM 576
KOMTRAX Terminal System 576
KOMTRAX Terminal 577
Input and Output Signals 578
20 – STANDARD VALUE TABLES 579
STANDARD VALUE TABLES 580
Standard Service Value Table for Engine 580
Standard Service Value Table for Chassis 581
MACHINE POSTURE 588
30 – TESTING AND ADJUSTING 591
TOOLS 595
Tools for Testing, Adjusting, and Troubleshooting 595
ENGINE COMPONENTS 599
Measuring Engine Speed 599
Measuring Exhaust Gas Color 602
Using Handy Smoke Checker (A1) 602
Using Smoke Meter (A2) 602
Measuring Exhaust Temperature 604
Adjusting Valve Clearance 606
Testing Compression Pressure 608
Measuring Blow-By Pressure 611
Measuring Engine Oil Pressure 613
Measuring Intake Air (Boost) Pressure 614
FUEL SYSTEM 616
Handling Fuel System Equipment 616
Releasing Residual Pressure in Fuel System 616
Testing Fuel Pressure 617
Testing Fuel Return Rate and Leakage 618
Bleeding Air from Fuel Circuit 622
Testing Leakage in Fuel System 624
Handling Reduced-Cylinder Mode Operation 625
Handling No-Injection Cranking Operation 625
Handling Controller Voltage Circuit 625
BELTS 626
Alternator Belt Tension 626
Air Conditioner Compressor Belt Tension 627
TRANSMISSION SPEED SENSOR 628
DIRECTIONAL LEVER 630
POWER TRAIN OIL PRESSURES 631
Measuring 633
Transmission Main Relief Pressure 633
Torque Converter Relief Pressure 634
Torque Converter Outlet Pressure 635
Lockup Clutch Pressure 636
F (Forward) Clutch Pressure 637
R (Reverse) Clutch Pressure 638
1st Clutch Pressure 639
2nd Clutch Pressure 640
3rd Clutch Pressure 641
4th Clutch Pressure 642
Lubrication Pressure 643
Adjusting 644
Transmission Main Relief Valve 644
Torque Converter Relief Valve 644
FLUSHING TRANSMISSION SYSTEM 645
Torque Converter and Transmission Hydraulic Circuit 645
WHEN TRANSMISSION VALVE FAILS 648
Moving Machine when Transmission Valve is Broken 648
STEERING SYSTEM 650
Steering Stop Valve 650
Testing 650
Adjusting 651
Steering Wheel 652
Measuring Play 652
Measuring Operating Effort 653
Measuring Operating Time 654
Steering Oil Pressure 655
Measuring Steering Relief Pressure 655
Measuring Pilot Circuit Pressure 657
Measuring LS Circuit Pressure 658
Adjusting Steering Relief Pressure 659
Bleeding Air From Steering Cylinder Circuit 660
HYDRAULIC FAN 661
Measuring Fan Speed 661
Measuring Fan Drive Oil Pressure 662
Measuring Fan Reverse Solenoid Output Pressure 663
Bleeding Air from Hydraulic Drive Fan Circuit 664
BRAKE SYSTEM 666
Measuring Brake Pedal 666
Measuring Brake Performance 667
Accumulator Charge Pressure 668
Testing Wheel Brake Oil Pressure 671
Measuring Wear of Brake Disc 673
Bleeding Air from Brake Circuit 0
Bleeding Air from Brake Cylinder 676
Releasing Residual Pressure in Brake Accumulator Circuit 677
Parking Brake 678
Testing Parking Brake Performance 678
Measuring Parking Brake Oil Pressure 679
Testing Wear of Parking Brake Disc 683
Releasing Parking Brake Manually 684
WORK EQUIPMENT 685
Control Lever 685
Measuring Operating Effort 685
Measuring Stroke 685
PPC Oil Pressure 686
Shutoff Valve Basic Pressure 686
Shut-off Valve Output Pressure 688
Oil Pressure 689
Preparation Work 689
Measuring Work Equipment Relief Pressure 689
Measuring Unload Pressure 690
Measuring LS Differential Pressure 691
Adjusting Unload Valve 694
Adjusting Work Equipment Relief Pressure 694
Adjusting LS Differential Pressure 695
Bleeding Air from Work Equipment Circuit 696
From Work Equipment Pump (piston pump) 696
From Hydraulic Cylinder 696
Releasing Residual Pressure in Hydraulic Circuit 697
Between Respective Hydraulic Cylinders and Control Valve 697
From ECSS (Travel Damper) Circuit 697
Moving Machine When Removing Operator Cab 698
Bucket Positioner 699
Testing and Adjusting 699
Adjusting Clearance 699
Adjusting Bucket-Levelness Detecting Proximity Switch 700
Adjusting Maximum Tilt-Detecting Proximity Switch 701
Position-Detecting Lever 702
Checking Proximity Switch Operation Pilot Lamp 703
ELECTRICAL SYSTEM 704
Troubleshooting 704
Procedure for Testing Diodes 704
Using Digital-Type Circuit Tester 704
Using Analog-Type Circuit Tester 705
Preparation Work for Troubleshooting Electrical System 706
Machine Monitor 706
Transmission Controller 707
Work Equipment Controller 708
KOMTRAX Terminal 708
KOMTRAX TERMINAL SYSTEM 709
Starting KOMTRAX Terminal Operations 709
Station Opening Check in Machine Side 709
Application for the Start of Use 713
KOMTRAX Terminal Indicator Lamps (if equipped) 714
MACHINE MONITOR SYSTEM 717
Adjusting Replaced, Reassembled, or Added Sensors and Controllers 717
Adjustment for User’s Needs 718
Normal and Special Functions of Machine Monitor 719
Normal Functions: Operator Mode 719
Special Functions: Service Mode 719
Functions and Flow of Service Mode 720
Operator Mode 723
Service Meter/Clock Display Function (1) 723
Load Meter Function (if equipped) (2) 723
Odometer Display Function (3) 723
Maintenance Monitoring Function (4) 724
Telephone Number Input Function (5) 724
Language Selection Function (6) 724
Monitor Brightness Adjustment Function (7) 724
Time Adjustment Function (8) 725
Travel Speed/Engine Speed Display Selecting Function (9) 725
Travel Speed/Engine Speed Display/Non-Display Selecting Function (10) 725
Action Code Display Function (11) 726
Failure Code Display Function (12) 726
Service Mode 728
Switching to Service Mode and Screen Display (1) 728
Electrical System Failure History Display Function (ELECTRIC FAULT) (2) 730
Mechanical System Failure History Display Function (MACHINE FAULT) (3) 732
Real-Time Monitoring Function (REAL-TIME MONITOR) (4) 733
Real-Time Monitoring Codes Tables 736
Cylinder Cutout Function (CYLINDER CUT-OUT) (5) 761
No-Injection Cranking Function (NO INJECTION) (6) 762
Adjustment Function (TUNING) (7) 763
Maintenance Monitoring Function (MAINTENANCE MONITOR) (8) 794
Operating Information Display Function (OPERATION INFO) (9) 799
Optional Device Selecting Function (OPTIONAL SELECT) (10) 802
Machine Serial Number Input Function (MACHINE No SET) (11) 806
Model Selection Function (MACHINE WA500) (12) 807
Initialize Function (INITIALIZE) (13) 808
PM CLINIC INSPECTION TABLES 809
40 – TROUBLESHOOTING 813
TROUBLESHOOTING POINTS 829
TROUBLESHOOTING EVENTS 831
MAINTENANCE PRECAUTIONS 832
Precautions when Handling Electrical Equipment 832
Handling Electronic Control Unit 837
Points to Remember When Troubleshooting Electrical Circuits 838
ELECTRIC WIRE CODE 839
How to Read Electric Wire Code 839
Type, Symbol, and Material 839
Dimensions 840
Color Codes Table 841
Circuits and Color Codes 842
Classification by Thickness 842
HANDLING HYDRAULIC EQUIPMENT 843
CHECKS BEFORE TROUBLESHOOTING 845
Categories and Method of Using Troubleshooting Charts 846
Troubleshooting Individual Electrical Circuits 847
Chart Use 849
Chart Tips 849
Troubleshooting Individual Hydraulic Circuits 850
CONNECTOR PIN NUMBERS 852
Connection Tables for Connector PIN Numbers 852
X-Type Connectors 852
SWP-Type Connectors 854
M-Type Connectors 856
S-Type Connectors 858
MIC-Type Connectors 860
AMP040-Type Connectors 862
AMP070-Type Connectors 864
AMP Connector 866
L-Type Connector 866
PA-Type Connector 867
Bendix (MS) Connector 867
KES1 (Automobile) Connectors 868
F-Type Connector 869
Connectors for Relay (Socket-Type) 870
HD30 Series Connectors 871
DT Series Connectors 876
DTM Series Connectors 878
DTHD Series Connectors 878
DTP Series Connectors 879
DRC26 Series Connectors 880
DRC12, 16 Series Connectors 882
AMP Connectors for Pump Controller (CH700) 883
BOSCH Connectors for Engine 884
SUMITOMO Connectors for Engine 885
CANNON Connector for Engine 886
AMP Connectors for Engine 887
FRAMATOME Connectors for Engine 888
PACKARD Connectors for Engine 890
DT Series Connectors for Engine 891
T-BRANCH BOX and T-BRANCH ADAPTER TABLE 892
MODE CHART 897
INFORMATION IN TESTING PROCEDURES 900
TROUBLESHOOTING BY FAILURE CODE 902
Failure Code Table 902
FUSE BOX AND SLOW-BLOW FUSES 916
Connection Table 916
Fuse Box A 916
Fuse Box B 916
Slow-Blow Fuses 917
FAILURE CODES 918
1500LO 919
TORQFLOW Transmission: Double Meshing 919
15BONX 920
Transmission Filter: Clogging 920
15SAL1 922
ECMV F Clutch: When Command Current is OFF, Fill Signal is ON 922
15SALH 924
ECMV F Clutch: When Command Current is ON, Fill Signal is OFF 924
15SBL1 926
ECMV R Clutch: When Command Current is OFF, Fill Signal is ON 926
15SBLH 928
ECMV R Clutch: When Command Current is ON, Fill Signal is OFF 928
15SEL1 930
ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON 930
15SELH 932
ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF 932
15SFL1 934
ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON 934
15SFLH 936
ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF 936
15SGL1 938
ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON 938
15SGLH 940
ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF 940
15SHL1 942
ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON 942
15SHLH 944
ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF 944
2F00MA 946
Parking Brake: Malfunction 946
2G42ZG 948
Front Accumulator: Low Oil Pressure 948
2G43ZG 950
Rear Accumulator: Low Oil Pressure 950
44K0L4 952
Bucket Positioner: ON/OFF Signals Disagree 952
AA1ANX 954
Air Cleaner: Clogging 954
AB00L6 956
Alternator: Signal Disagrees with Operating State of Engine 956
AB00MA 958
Alternator: Malfunction 958
B@BAZG 960
Engine: Low Engine Oil Pressure 960
B@BAZK 962
Engine Oil: Low Level 962
B@BCNS 964
Engine: Coolant: Overheating 964
B@BCZK 966
Engine: Coolant: Low Level 966
B@C7NS 968
Brake: Brake Oil: Overheating 968
b@CENS 970
Torque Converter Oil: Overheating 970
B@CENS 972
Torque Converter Oil: Overheating 972
B@GAZK 974
Battery Electrolyte: Low Level 974
B@HANS 976
Hydraulic Oil: Overheating 976
CA111 978
Abnormality in Engine Controller 978
CA115 981
Engine Ne or Bkup Speed Sensor Error 981
CA122 982
Charge Pressure Sensor High Error 982
CA123 984
Charge Pressure Sensor Low Error 984
CA131 986
Throttle Sensor High Error 986
CA132 988
Throttle Sensor Low Error 988
CA135 990
Engine Oil Pressure Sensor High Error 990
CA141 992
Engine Oil Pressure Sensor Low Error 992
CA144 994
Coolant Temperature Sensor High Error 994
CA145 996
Coolant Temperature Sensor Low Error 996
CA153 998
Charge Temperature Sensor High Error 998
CA154 1000
Charge Temperature Sensor Low Error 1000
CA187 1001
Sensor Power Supply 2 Low Error 1001
CA221 1002
Atmospheric Pressure Sensor High Error 1002
CA222 1004
Atmospheric Pressure Sensor Low Error 1004
CA227 1006
Sensor Power Supply 2 High Error 1006
CA234 1008
Engine Overspeed 1008
CA238 1010
Ne Speed Sensor Power Supply Error 1010
CA263 1012
Fuel Temperature Sensor High Error 1012
CA265 1014
Fuel Temperature Sensor Low Error 1014
CA271 1016
PCV1 Short Circuit 1016
CA272 1018
PCV1 Disconnection 1018
CA273 1020
PCV2 Short Circuit 1020
CA274 1022
PCV2 Disconnection 1022
CA322 1024
Injector #1 (L/B #1) Open/Short Error 1024
CA323 1026
Injector #5 (L/B #5) Open/Short Error 1026
CA324 1028
Injector #3 (L/B #3) Open/Short Error 1028
CA325 1030
Injector #6 (L/B #6) Open/Short Error 1030
CA331 1032
Injector #2 (L/B #2) Open/Short Error 1032
CA332 1034
Injector #4 (L/B #4) Open/Short Error 1034
CA342 1036
Calibration Code Data Inconsistency 1036
CA351 1037
Injectors Drive Circuit Error 1037
CA352 1040
Sensor Power Supply 1 Low Error 1040
CA386 1042
Sensor Power Supply 1 High Error 1042
CA431 1044
Idle Validation Switch Error 1044
CA432 1046
Idle Validation Action Error 1046
CA441 1047
Battery Voltage Low Error 1047
CA442 1048
Battery Voltage High Error 1048
CA449 1049
Common Rail Pressure High Error 2 1049
CA451 1050
Common Rail Pressure Sensor High Error 1050
CA452 1052
Common Rail Pressure Sensor Low Error 1052
CA553 1053
Common Rail Pressure High Error 1 1053
CA554 1054
Common Rail Pressure In-Range Error 1054
CA559 1056
Supply Pump Pressure Very Low Error 1 1056
Checksheet for No-Pressure Feed 1058
CA689 1060
Engine Ne Speed Sensor Error 1060
CA731 1062
Engine Bkup Speed Sensor Phase Error 1062
CA757 1063
All Continuous Data Lost Error 1063
CA778 1064
Engine Bkup Speed Sensor Error 1064
CA1228 1066
EGR Valve Servo Error 1 1066
CA1625 1067
EGR Valve Servo Error 2 1067
CA1626 1068
Bypass Valve Solenoid Current High Error 1068
CA1627 1070
Bypass Valve Solenoid Drive Circuit Disconnection Error 1070
CA1628 1071
Bypass Valve Servo Error 1 1071
CA1629 1072
Bypass Valve Servo Error 2 1072
CA1631 1074
Bypass Valve Lift Sensor High Error 1074
CA1632 1076
Bypass Valve Lift Sensor Low Error 1076
CA1633 1077
KOMNET Datalink Timeout Error 1077
CA1642 1078
Abnormally Low Signal in EGR Inlet Pressure Sensor 1078
EGR Inlet Pressure Sensor Low Error 1079
CA1653 1080
Abnormally High Signal in EGR Inlet Pressure Sensor 1080
EGR Inlet Pressure Sensor High Error 1082
CA2185 1084
Throttle Sensor Supply Voltage High Error 1084
CA2186 1086
Throttle Sensor Power Supply Low Error 1086
CA2249 1087
Supply Pump Pressure Very Low Error 2 1087
CA2271 1088
EGR Valve Lift Sensor High Error 1088
CA2272 1090
EGR Valve Lift Sensor Low Error 1090
CA2351 1092
EGR Valve Solenoid Operation Short Circuit 1092
CA2352 1094
EGR Valve Solenoid Operation Disconnection Error 1094
CA2555 1095
Intake Heater Relay Disconnection Error 1095
CA2556 1096
Intake Heater Relay Short Circuit Error 1096
D160KZ 1098
Backup Lamp Relay: Disconnection or Short Circuit 1098
D191KA 1100
Joystick Steering Neutral Safety Relay: Disconnection 1100
D191KB 1102
Joystick Steering Neutral Safety Relay: Short Circuit 1102
D192KA 1104
ECSS Solenoid: Disconnection 1104
D192KB 1105
ECSS Solenoid: Short Circuit 1105
D192KY 1106
ECSS Solenoid Relay: Short Circuit with Power Supply Line 1106
D193KA 1108
Joystick Steering Solenoid Cut Relay: Disconnection 1108
D193KB 1110
Joystick Steering Solenoid Cut Relay: Short Circuit 1110
D193KY 1112
Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line 1112
D5ZHKA 1114
Terminal C Signal: Disconnection 1114
D5ZHKB 1118
Terminal C Signal: Short Circuit 1118
D5ZHKZ 1120
Terminal C Signal: Disconnection or Short Circuit 1120
D5ZHL6 1124
Terminal C Signal: Signal Does Not Match Engine Running or Stopped State 1124
DA80L4 1126
Auto-Grease Controller: ON/OFF Signals Disagree 1126
DAF3KK 1128
Machine Monitor: Low Source Voltage (input) 1128
DAF5KP 1130
Machine Monitor: Low Output Voltage 1130
DAFRKR 1134
Machine Monitor: CAN Defective Communication 1134
DAQ0KK 1136
Transmission Controller: Low Source Voltage 1136
DAQ0KT 1138
Transmission Controller: Abnormality in Controller 1138
DAQ2KK 1140
Transmission Controller Load Power Supply Line: Low Source Voltage (input) 1140
DAQ9KQ 1142
Transmission Controller: Disagreement of Model Selection Signals 1142
DAQRKR 1144
Transmission Controller: CAN Defective Communication 1144
DAQRMA 1146
Transmission Controller Option Setting: Malfunction 1146
DB2RKR 1148
Engine Controller: CAN Defective Communication 1148
DB90KK 1150
Work Equipment Controller: Low Source Voltage (input) 1150
DB90KT 1152
Work Equipment Controller: Abnormality in Controller 1152
DB92KK 1154
Work Equipment Controller Load Power Supply Line: Low Source Voltage (input) 1154
DB95KX 1156
Work Equipment Controller Power Supply Output: Out-of-Input Signal Range 1156
DB99KQ 1159
Work Equipment Controller: Disagreement of Model Selection Signals 1159
DB9RKR 1160
Work Equipment Controller: CAN Defective Communication 1160
DB9RMA 1162
Work Equipment Controller Option Setting: Malfunction 1162
DB9RMC 1164
Work Equipment Controller: CAN Communication Defective Operation 1164
DD15LD 1166
Switch (Panel Switch 1 n): Switch is Kept Pressed for Long Time 1166
DD16LD 1168
Switch (Panel Switch 2 ‡): Switch is Kept Pressed for Long Time 1168
DD17LD 1170
Switch (Panel Switch 3 <): Switch is Kept Pressed for Long Time 1170
DD18LD 1172
Switch (Panel Switch 4 >): Switch is Kept Pressed for Long Time 1172
DD1ALD 1174
Remote Positioner Raise/Lower Set Switch (raise): Switch Is Kept Pressed for Long Time 1174
DD1BLD 1176
Remote Positioner Raise/Lower Set Switch (lower): Switch is Kept Pressed for Long Time 1176
DD1CLD 1178
Load Meter Subtotal Switch: Switch is Kept Pressed for Long Time 1178
DD1FLD 1180
Load Meter Mode Selector Switch (A/B): Switch is Kept Pressed for Long Time 1180
DD1GLD 1182
Load Meter Mode Selector Switch (+/-): Switch is Kept Pressed for Long Time 1182
DD1HLD 1184
Load Meter Display Selector Switch: Switch is Kept Pressed for Long Time 1184
DDA7L4 1186
RPM Set ON/OFF Switch: ON/OFF Signals Disagree 1186
DDA8KB 1188
RPM Set Idle UP/DOWN Selector Switch (idle UP): Short Circuit 1188
DDA9KB 1190
RPM Set Idle UP/DOWN Selector Switch (idle DOWN): Short Circuit 1190
DDB6L4 1192
Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree 1192
DDD1LD 1196
Remote Positioner Bucket Angle Set Switch: Switch is Kept Pressed for Long Time 1196
DDE5MA 1198
Emergency Steering Drive Switch: Malfunction 1198
DDK3KA 1200
Right FNR Switch: Disconnection 1200
DDK3KB 1203
Right FNR Switch: Short Circuit 1203
DDK4KA 1206
Joystick Steering FNR Switch: Disconnection 1206
DDK4KB 1209
Joystick Steering FNR Switch: Short Circuit 1209
DDK5L4 1212
Joystick Steering with Shift UP/DOWN Switch: ON/OFF Signals Disagree 1212
DDK6KA 1214
FNR Lever Switch: Disconnection 1214
DDK6KB 1217
FNR Lever Switch: Short Circuit 1217
DDT0L4 1220
Shift Mode Selector Switch: ON/OFF Signals Disagree 1220
DDT4LD 1222
Transmission Cutoff Set Switch: Switch is Kept Pressed for Long Time 1222
DDW9LD 1224
Kickdown Switch: Switch is Kept Pressed for Long Time 1224
DDWLLD 1226
Hold Switch: Switch is Kept Pressed Down for Long Time 1226
DDY0LD 1228
Load Meter Cancel Switch: Switch is Kept Pressed for Long Time 1228
DF10KA 1230
Transmission Shift Lever Switch: Disconnection 1230
DF10KB 1233
Transmission Shift Lever Switch: Short Circuit 1233
DGF1KA 1236
Transmission Oil Temperature Sensor: Disconnection 1236
DGF1KB 1238
Transmission Oil Temperature Sensor: Short Circuit 1238
DGH2KX 1240
Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range 1240
DGR2KA 1242
Rear Brake Oil Temperature Sensor: Disconnection 1242
DGR2KX 1244
Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range 1244
DGT1KX 1246
Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range 1246
DH21KA 1248
Work Equipment Pump Oil Pressure Sensor: Disconnection 1248
DH21KB 1250
Work Equipment Pump Oil Pressure Sensor: Short Circuit 1250
DHPCKX 1252
Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range 1252
DHPDKX 1254
Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range 1254
DHT1KX 1256
Left Brake Pressure Sensor: Out-of-Input Signal 1256
DHT2L6 1258
Transmission Filter Clogging Sensor: Signal Disagrees with Operating and Stopped States of Engine 1258
DK59KA 1260
Lift Arm EPC Lever Potentiometer (Main): Disconnection 1260
DK59KY 1263
Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line 1263
DK59L8 1266
Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree 1266
DK5AKA 1270
Lift Arm EPC Lever Potentiometer (Sub): Disconnection 1270
DK5AKY 1273
Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne 1273
DK5BKA 1276
Bucket EPC Lever Potentiometer (Main): Disconnection 1276
DK5BKY 1279
Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line 1279
DK5BL8 1282
Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree 1282
DK5CKA 1285
Bucket EPC Lever Potentiometer (Sub): Disconnection 1285
DK5CKY 1288
Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line 1288
DK5DKA 1291
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Disconnection 1291
DK5DKY 1294
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line 1294
DK5DL8 1296
3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Analog Signals Disagree 1296
DK5EKA 1300
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Disconnection 1300
DK5EKY 1302
3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line 1302
DK5FKA 1304
Joystick Steering EPC Lever Potentiometer (Main): Disconnection 1304
DK5FKY 1306
Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line 1306
DK5GKA 1308
Joystick Steering EPC Lever Potentiometer (Sub): Disconnection 1308
DK5GKY 1310
Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line 1310
DK5FL8 1312
Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree 1312
DKA0KA 1316
Lift Arm Angle Sensor: Disconnection 1316
DKA0KX 1318
Lift Arm Angle Sensor: Out-of-Input Signal Range 1318
DKA0KY 1322
Lift Arm Angle Sensor: Short Circuit with Power Supply Line 1322
DKA0L0 1324
Lift Arm Angle Sensor: Double Meshing 1324
DLF1KA 1326
Transmission Input Shaft Speed Sensor: Disconnection 1326
DLF1LC 1328
Transmission Input Shaft Speed Sensor: Speed Signals Disagree 1328
DLT4KB 1330
Transmission Input Shaft Speed Sensor: Short Circuit 1330
DLT4KX 1332
Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range 1332
DT20KB 1334
Transmission Cutoff Indicator Lamp: Short Circuit 1334
DUM1KB 1336
Remote Positioner Raise Set Indicator Lamp: Short Circuit 1336
DUM2KB 1338
Remote Positioner Lower Set Indicator Lamp: Short Circuit 1338
DV00KB 1340
Alarm Buzzer: Short Circuit 1340
DW4PKA 1342
Lift Arm Raise EPC Solenoid: Disconnection 1342
DW4PKB 1344
Lift Arm Raise EPC Solenoid: Short Circuit 1344
DW4PKY 1346
Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line 1346
DW4QKA 1348
Lift Arm Lower EPC Solenoid: Disconnection 1348
DW4QKB 1350
Lift Arm Lower EPC Solenoid: Short Circuit 1350
DW4QKY 1352
Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line 1352
DW4RKA 1354
Bucket Tilt EPC Solenoid: Disconnection 1354
DW4RKB 1356
Bucket Tilt EPC Solenoid: Short Circuit 1356
DW4RKY 1358
Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line 1358
DW4SKA 1360
Buck Dump EPC Solenoid: Disconnection 1360
DW4SKB 1362
Bucket Dump EPC Solenoid: Short Circuit 1362
DW4SKY 1364
Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line 1364
DW7BKA 1366
Fan Reverse Solenoid: Disconnection 1366
DW7BKB 1368
Fan Reverse Solenoid: Short Circuit 1368
DW7BKY 1370
Fan Reverse Solenoid: Short Circuit with Power Supply Line 1370
DW7DKA 1372
Hydraulic Drive Fan Neutral Solenoid: Disconnection 1372
DW7DKB 1373
Hydraulic Drive Fan Neutral Solenoid: Short Circuit 1373
DW7DKY 1374
Hydraulic Drive Fan Solenoid: Short Circuit with Power Supply Line 1374
DWM1KA 1376
Work Equipment Neutral Lock Solenoid: Disconnection 1376
DWM1KB 1378
Work Equipment Neutral Lock Solenoid: Short Circuit 1378
DWM1KY 1380
Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line 1380
DWN6KA 1382
Lift Arm Raise Magnet Detent Solenoid: Disconnection 1382
DWN6KB 1384
Lift Arm Raise Magnet Detent Solenoid: Short Circuit 1384
DWN6KY 1386
Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line 1386
DWN7KA 1388
Lift Arm Float Magnet Detent Solenoid: Disconnection 1388
DWN7KB 1390
Lift Arm Float Magnet Detent Solenoid: Short Circuit 1390
DWN7KY 1392
Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line 1392
DWN8KA 1394
Bucket Tilt Magnet Detent Solenoid: Disconnection 1394
DWN8KB 1396
Bucket Tilt Magnet Detent Solenoid: Short Circuit 1396
DWN8KY 1398
Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source 1398
DX16KA 1400
Fan Pump EPC Solenoid: Disconnection 1400
DX16KB 1401
Fan Pump EPC Solenoid: Short Circuit 1401
DX16KY 1402
Fan Pump EPC Solenoid: Short Circuit with Power Supply Line 1402
DXA1KA 1403
Pump PC-EPC Solenoid: Disconnection 1403
DXA1KB 1404
Pump PC-EPC Solenoid: Short Circuit 1404
DXH1KA 1406
Lockup ECMV Solenoid: Disconnection 1406
DXH1KB 1408
Lockup ECMV Solenoid: Short Circuit 1408
DXH1KY 1410
Lockup ECMV Solenoid: Short Circuit with Power Supply Line 1410
DXH4KA 1412
1st Clutch ECMV Solenoid: Disconnection 1412
DXH4KB 1414
1st Clutch ECMV Solenoid: Short Circuit 1414
DXH4KY 1416
1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1416
DXH5KA 1418
2nd Clutch ECMV Solenoid: Disconnection 1418
DXH5KB 1420
2nd Clutch ECMV Solenoid: Short Circuit 1420
DXH5KY 1422
2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1422
DXH6KA 1424
3rd Clutch ECMV Solenoid: Disconnection 1424
DXH6KB 1426
3rd Clutch ECMV Solenoid: Short Circuit 1426
DXH6KY 1428
3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1428
DXH7KA 1430
R Clutch ECMV Solenoid: Disconnection 1430
DXH7KB 1432
R Clutch ECMV Solenoid: Short Circuit 1432
DXH7KY 1434
R Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1434
DXH8KA 1436
F Clutch ECMV Solenoid: Disconnection 1436
DXH8KB 1438
F Clutch ECMV Solenoid: Short Circuit 1438
DXH8KY 1440
F Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1440
DXHHKA 1442
4th Clutch ECMV Solenoid: Disconnection 1442
DXHHKB 1444
4th Clutch ECMV Solenoid: Short Circuit 1444
DXHHKY 1446
4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line 1446
DXHJKA 1448
3-Spool Valve Extract EPC Solenoid: Disconnection 1448
DXHJKB 1449
3-Spool Valve Extract EPC Solenoid: Short Circuit 1449
DXHJKY 1450
3-Spool Valve Extract EPC Solenoid: Short Circuit with Power Supply Line 1450
DXHKKA 1452
3-Spool Valve Retract EPC Solenoid: Disconnection 1452
DXHKKB 1453
3-Spool Valve Retract EPC Solenoid: Short Circuit 1453
DXHKKY 1454
3-Spool Valve Retract EPC Solenoid: Short Circuit with Power Supply Line 1454
DXHLKA 1456
Joystick Steering Right EPC Solenoid: Disconnection 1456
DXHLKB 1458
Joystick Steering Right EPC Solenoid: Short Circuit 1458
DXHLKY 1461
Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line 1461
DXHMKA 1464
Joystick Steering Left EPC Solenoid: Disconnection 1464
DXHMKB 1466
Joystick Steering Left EPC Solenoid: Short Circuit 1466
DXHMKY 1469
Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line 1469
TROUBLESHOOTING: E-MODE 1472
Troubleshooting Electrical System 1472
Information in Troubleshooting Table 1472
E-1 1474
Engine Does Not Start 1474
E-2 1480
Wiper Does Not Operate 1480
E-3 1484
Windshield Washer Does Not Operate 1484
E-4 1488
Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off 1488
E-5 1496
Working Lamp Does Not Light Up or Go Off 1496
E-6 1502
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off 1502
E-7 1508
Brake Lamp Does Not Light or It Keeps Lighting Up 1508
E-8 1512
Backup Lamp Does Not Light or It Keeps Lighting Up 1512
E-9 1514
Backup Buzzer Does Not Sound or It Keeps Sounding 1514
E-10 1516
Horn Does Not Sound or It Keeps Sounding 1516
E-11 1520
Alarm Buzzer Does Not Sound or It Keeps Sounding 1520
E-12 1522
Air Conditioner Does Not Operate or Stop 1522
E-13 1526
KOMTRAX System Does Not Work Properly 1526
Lamp Display Section of KOMTRAX Terminal 1528
TROUBLESHOOTING: H-MODE 1530
Troubleshooting Hydraulic and Mechanical Systems 1530
Using Troubleshooting Chart 1530
Failure Codes and Causes Table 1532
H-1 1536
Machine Does Not Start 1536
H-2 1538
Torque Converter Lockup is Not Switched OFF (Engine Stalls) 1538
H-3 1539
Torque Converter Lockup is Not Switched ON 1539
H-4 1540
Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted 1540
H-5 1542
Large Shocks When Starting and Shifting Gears 1542
H-6 1543
Large Time Lag When Starting and Shifting Gear 1543
H-7 1544
Torque Converter Oil Temperature is High 1544
H-8 1545
Steering Does Not Turn 1545
H-9 1546
Steering Does Not Turn (Joystick Steering, if equipped) 1546
H-10 1547
Steering Response is Poor 1547
H-11 1548
Steering Turning Response is Poor (Joystick Steering, if Equipped) 1548
H-12 1549
Steering is Heavy 1549
H-13 1550
When Machine Turns, It Shakes or Jerks 1550
H-14 1551
When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped) 1551
H-15 1552
Wheel Brake Does Not Work or Does Not Work Well 1552
H-16 1553
Wheel Brake is Not Released or It Drags 1553
H-17 1554
Parking Brake Does Not Work or Does Not Work Well 1554
H-18 1555
Parking Brake is Not Released or It Drags 1555
H-19 1556
Lift Arm Does Not Rise 1556
H-20 1557
Lift Arm is Low or Rising Force is Insufficient 1557
H-21 1558
When Rising, Lift Arm Starts to Move Slowly at a Specific Height 1558
H-22 1558
Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats) 1558
H-23 1558
Hydraulic Drifts of the Lift Arm Occur Often 1558
H-24 1559
Lift Arm Wobbles During Operation 1559
H-25 1560
Bucket Does Not Tilt Back 1560
H-26 1561
Bucket Speed is Low or Tilting-Back Force Is Insufficient 1561
H-27 1562
Bucket Starts to Operate Slowly in the Midst of Tilting Back 1562
H-28 1562
Bucket Cylinder Cannot Hold Down the Bucket 1562
H-29 1562
Hydraulic Drifts of the Bucket Occur Often 1562
H-30 1563
Bucket Wobbles During Travel with Load 1563
H-31 1563
During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls 1563
H-32 1563
Large Shocks When Work Equipment Starts and Stops 1563
H-33 1563
When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves 1563
H-34 1564
ECSS Does Not Operate; Pitching and Bouncing Occur 1564
50 – DISASSEMBLY AND ASSEMBLY 1565
HOW TO READ THIS MANUAL 1570
Removal and Installation of Assemblies 1570
Disassembly and Assembly of Assemblies 1572
COATING MATERIALS LIST 1574
SPECIAL TOOLS LIST 1578
SKETCHES OF SPECIAL TOOLS 1583
CONNECTOR REPAIR PROCEDURES 1590
Stripping Insulation 1590
Wire Inspection 1590
Contact Terminal Removal (HD30 Type) 1591
Crimping Contact Terminal (HD30 Type) 1592
Insertion of Contact Terminal (HD30 Type) 1593
Contact Terminal Removal (DT Type) 1594
Crimping Contact Terminal (DT Type) 1595
Insertion of Contact Terminal (DT Type) 1596
ENGINE AND COOLING SYSTEM 1598
Engine 1598
Removal 1598
Installation 1604
Radiator 1606
Removal 1606
Installation 1608
Air Aftercooler 1609
Removal 1609
Installation 1610
Cooling Fan and Fan Motor 1611
Removal 1611
Installation 1613
Radiator Guard and Cooling Fan 1614
Removal 1614
Installation 1617
Fuel Tank 1618
Removal 1618
Installation 1620
Engine Hood 1621
Removal 1621
Installation 1624
Fuel Supply Pump 1625
Removal 1625
Installation 1629
Cylinder Head 1631
Removal 1631
Installation 1641
Fuel Injector 1647
Removal 1647
Installation 1649
Engine Front Seal 1651
Removal 1651
Installation 1653
Engine Rear Seal 1656
Removal 1656
Installation 1659
POWER TRAIN 1663
Torque Converter and Transmission Assembly 1663
Removal 1663
Installation 1670
Power Train 1672
Preparation 1672
Disassembly 1674
Assembly 1676
Input Transfer 1678
Disassembly 1678
Assembly 1682
Torque Converter (Lockup Specification) 1687
Disassembly 1687
Assembly 1695
Torque Converter (Without Lockup) 1705
Disassembly 1705
Assembly 1712
Transmission 1720
Disassembly 1720
Assembly 1739
Transfer and Parking Brake Assembly 1760
Disassembly 1761
Assembly 1771
Front Axle 1783
Removal 1783
Installation 1785
Rear Axle 1786
Removal 1786
Installation 1788
Front Differential 1789
Removal 1789
Installation 1790
Differential (with Limited Slip Differential) 1791
Disassembly 1791
Assembly 1797
Differential (without Limited Slip Differential) 1809
Disassembly 1809
Assembly 1815
Final Drive (Front and Rear) 1824
Disassembly 1824
Assembly 1828
BRAKE SYSTEM 1833
Brakes (Front and Rear) 1833
Removal 1833
Installation 1835
Disassembly 1836
Assembly 1840
Slack Adjuster 1844
Brake Accumulator Charge Valve 1845
UNDERCARRIAGE AND FRAME 1846
Center Hinge Pin 1846
Removal 1847
Installation 1851
HYDRAULIC SYSTEM 1856
Hydraulic Tank 1856
Removal 1856
Installation 1860
Cooling Pump 1861
Removal 1861
Installation 1862
Fan Pump 1863
Removal 1863
Installation 1864
Work Equipment Pump 1865
Removal 1865
Installation 1867
Steering, Torque Converter Charge, and EPC Pump Assembly 1868
Removal 1868
Installation 1869
Work Equipment Valve 1870
Removal 1870
Installation 1873
Work Equipment Control Valve Assembly 1874
Disassembly and Assembly 1874
Steering Cylinder 1878
Disassembly 1878
Assembly 1881
Lift Arm and Bucket Cylinder 1883
Disassembly 1883
Assembly 1887
Steering Valve 1892
Removal 1892
Installation 1893
WORK EQUIPMENT 1894
Work Equipment 1894
Removal 1894
Installation 1898
Counterweight (Large) 1900
Removal 1900
Installation 1901
Counterweight (Small) 1902
Removal 1902
Installation 1902
CAB AND ITS ATTACHMENTS 1903
Cab (Separate Cab and Floor) 1903
Removal 1903
Installation 1910
Cab and Floor Frame (Cab-Floor Unit) 1911
Installation 1916
Cab Glass (Stuck Glass) 1917
Removal 1918
Installation 1919
Operator Seat (Upper Seat) 1927
Storage Box 1927
Seat Pad and Backrest Upholstery 1927
Mechanical Lumbar Support 1928
Armrests (if equipped) 1929
Backrest 1930
Backrest Adjustment 1932
Seat Angle and Seat Depth Adjuster 1933
Covers 1935
Slide Rails 1936
Operator Seat (Suspension) 1937
Top Cover 1937
Front Cover 1937
Bellows 1938
Bowden Pull Wire and Handle (Vertical Shock Absorber Adjustment) 1940
Vertical Shock Absorber 1944
ELECTRICAL SYSTEM 1982
Engine Controller 1982
Removal 1982
Installation 1982
Transmission Controller 1983
Removal 1983
Installation 1983
Work Equipment Controller 1984
Removal 1984
Installation 1984
KOMTRAX Terminal 1985
Removal 1985
Installation 1985
Air Conditioner Unit 1986
Removal 1986
Installation 1990
60 – AIR CONDITIONER 1991
PRECAUTIONS FOR REFRIGERANT 1993
TROUBLESHOOTING PROCEDURE 1994
Basic Flow of Troubleshooting 1994
CIRCUIT DIAGRAM AND CONNECTOR PINS 1996
SYSTEM DIAGRAM 2001
DETAIL OF AIR CONDITIONER UNIT 2003
Parts and Connectors Layout 2005
Testing with Self-Diagnosis Function (Control Panel Display) 2009
Testing Temperature Control 2012
Testing Vent (Mode) Changeover 2013
Testing Fresh/Recirc Changeover 2016
Testing Inside and Outside Air Temp Sensor 2018
Testing Evaporator Temperature Sensor 2020
Testing Sunlight Sensor 2021
Testing Relays 1 2022
TROUBLESHOOTING CHART 1 2023
TROUBLESHOOTING CHART 2 2024
INFORMATION IN TROUBLESHOOTING TABLE 2027
TROUBLESHOOTING FOR POWER 2028
Air Conditioner Does Not Operate 2028
TROUBLESHOOTING COMPRESSOR AND REFRIGERANT SYSTEM 2031
Air is Not Cooled 2031
TROUBLESHOOTING FOR BLOWER MOTOR 2034
No Air Comes Out or Air Flow is Abnormal 2034
TROUBLESHOOTING TEMPERATURE CONTROL 2040
TROUBLESHOOTING VENT (MODE) CHANGEOVER 2043
Machine Equipped With Automatic Air Conditioner 2043
TROUBLESHOOTING FRESH/RECIRC AIR CHANGEOVER 2046
Machine Equipped With Automatic Air Conditioner 2046
TROUBLESHOOTING WITH GAUGE PRESSURE 2048
CONNECTION OF SERVICE TOOL 2050
HANDLING OF COMPRESSOR OIL 2051
90 – DIAGRAMS AND SCHEMATICS 2053
90 DIAGRAMS AND SCHEMATICS 2053
HYDRAULIC SYSTEM 2055
Power Train Hydraulic Circuit 2055
Without Lockup Clutch 2055
With Lockup Clutch 2056
Brake Hydraulic Circuit 2057
Without Forced Brake Cooling System 2057
With Forced Brake Cooling System 2058
Work Equipment 2059
ELECTRICAL SYSTEM 2060
Air Conditioner Electrical Circuit 2060
Electrical Circuit Diagram (1/7) 2061
Electrical Circuit Diagram (2/7) 2062
Electrical Circuit Diagram (3/7) 2063
Electrical Circuit Diagram (4/7) 2064
Electrical Circuit Diagram (5/7) 2065
Electrical Circuit Diagram (6/7) 2066
Electrical Circuit Diagram (7/7) 2067
Connector List and Stereogram 2068
Chassis 2068
Operator’s Compartment 2069
Engine and Transmission 2070

DESCRIPTION:

Komatsu WA500-6 Wheel Loader Shop Manual CEBM022903 – PDF DOWNLOAD 

SERIAL NUMBERS WA500-6 A93001 and UP

Precautions when Completing the Operation 
1. Refilling with coolant, oil, and grease
• If the coolant has been drained:
• Tighten the drain valve and add coolant to the specified level.
• Run the engine to circulate the coolant through the system.
• Check the coolant level again.
• If the hydraulic equipment has been removed and installed again:
• Add engine oil to the specified level.
• Run the engine to circulate the oil through the system.
• Check the oil level again.
• If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassembling the
parts.
★ For details, see WORK EQUIPMENT: Bleeding Air from Work Equipment Circuit in the Testing and Adjusting
section.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
2. Checking cylinder head and manifolds for looseness
• Check the cylinder head and intake and exhaust manifold for looseness.
• If any part is loosened, retighten it.
★ For the tightening torque, see ENGINE AND COOLING SYSTEM: Cylinder Head in the Disassembly and
Assembly section.
3. Checking engine piping for damage and looseness
• Intake and exhaust system
• Check the piping for damage; the mounting bolts and nuts for looseness; and the joints for air suction and
exhaust gas leakage.
• If any part is loosened or damaged, retighten or repair it.
• Cooling system
• Check the piping for damage; the mounting bolts and nuts for looseness; and the joints for coolant leakage.
• If any part is loosened or damaged, retighten or repair it.
• Fuel system
• Check the piping for damage; the mounting bolts and nuts for looseness; and the joints for fuel leakage.
• If any part is loosened or damaged, retighten or repair it.

S.V 12/12/24