Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-19 Serial 55001 and Up

Description

Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-19 Serial 55001 and Up

This Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-19 Serial 55001 and Up is the chassis shop volume used to service the WA500-6 wheel loader from serial number 55001 and up. It walks a technician from specification data through structure and maintenance standards, standard service values, testing and adjusting, failure-code troubleshooting, mechanical and electrical fault charts, and full disassembly and assembly of the major units. The binder form is SEN00236-19; related section forms include SEN00701-19 (index), SEN00702-05 (foreword), SEN00703-03 (specification), and the numbered structure, testing, troubleshooting, and dismantling books listed in the composition table. Copyright on the index form is 2017 Komatsu, printed in Japan 07-17 (01). Cover marking also shows ecoT3.

The shop manual itself states that Komatsu shop manuals are split into a chassis volume and an engine volume. This file is the chassis book for the machine. For complete engine-unit overhaul of the mounted engine, the engine volume for that engine model is required in addition to this chassis volume. Even so, this WA500-6 shop manual still carries chassis-side engine work: cooling-system structure, engine and transmission mounts, compression and blow-by checks, fuel-system handling for the common-rail installation, engine-controller failure codes, S-mode engine troubleshooting charts, and removal of the engine assembly, cylinder head, injectors, supply pump, and front and rear seals.

File Details

• Manual type: Shop Manual (chassis volume)
• Brand / model: Komatsu WA500-6 wheel loader
• Serial range: 55001 and up
• Engine identified in specification: SAA6D140E-5
• Language: English
• Page count: 1864
• File format: PDF
• Binder / contents form: SEN00236-19
• Index form: SEN00701-19
• Foreword form: SEN00702-05
• Specification form: SEN00703-03
• Print note: © 2017 Komatsu, Printed in Japan 07-17 (01)

Machine identity in the specification book

Section 01 records the machine as WA500-6, serial 55001 and up, with an operating weight of 32,230 kg, front wheel load 15,090 kg, and rear wheel load 17,140 kg. Heaped bucket capacity is 5.6 m³ with bolt-on cutting edge; rated load is 9,250 kg. Travel speeds are F1 7.7 km/h, F2 12.5 km/h, F3 22.3 km/h, F4 34.9 km/h and R1 8.6 km/h, R2 13.0 km/h, R3 24.8 km/h, R4 37.5 km/h. Maximum drawbar pull is 288.3 kN {29,400 kg} forward and 256.4 kN {26,150 kg} reverse. Gradeability is 25 degrees. Minimum turning radius at the center of the outside tire is 6,430 mm; turning radius at the bolt-on cutting-edge tip is 7,650 mm.

Overall length is 9,815 mm with BOC, overall width 3,190 mm, bucket width 3,400 mm with BOC, overall height at ROPS cab top 3,785 mm, overall height with bucket lifted 6,430 mm, wheelbase 3,780 mm, tread 2,400 mm, and minimum ground clearance 450 mm. Maximum hinge-pin height is 4,755 mm, dumping clearance 3,295 mm with BOC, dumping reach 1,500 mm with BOC, bucket tilt-forward angle 46 degrees, tilt-back angle in operating posture 50 degrees, and digging depth about 435 mm at approximately 10 degrees.

The engine line in the same specification table is SAA6D140E-5: 4-cycle, water-cooled, direct injection, turbocharged, with air-cooled aftercooler and water-cooled EGR. Cylinders, bore and stroke are 6 – 140 x 165 mm. Total piston displacement is 15.2 ℓ {15,240 cc}. Flywheel horsepower is 263 kW / 1,900 rpm {353 HP / 1,900 rpm}. Fuel consumption rate at rated speed is 216.2 g/kWh {161 g/HP·h}. Maximum no-load speed is 2,150 rpm and minimum no-load speed is 675 rpm. Starting motor is 24 V, 11 kW; alternator 24 V, 75 A; batteries 12 V, 170 Ah x 2.

Power train description in that table is a 3-element, 1-stage, 2-phase torque converter; planetary multi-disc transmission with four forward and four reverse speeds; spiral-bevel reduction gear with splash lubrication; straight-bevel differential; and planetary single-reduction final drives with splash lubrication. Drive is front and rear. Front axle is fixed-frame full-float; rear axle is center-pin support full-float. Standard tire size is 29.5-25-33-22PR(L3) on 25.00 x 25WTB rims, inflation 440 kPa {4.5 kg/cm²} front and 392 kPa {4.0 kg/cm²} rear. Foot brakes are independent front and rear enclosed wet multi-disc units; the parking brake is a hydraulically released, spring-applied wet-disc unit on the drive shaft.

Steering is articulated, fully hydraulic. Pump deliveries listed are work equipment HPV190 variable piston pump 321 ℓ/min, steering LPV90 120 ℓ/min, cooling-fan LPV45 70 ℓ/min, power-train gear pump SAR (3) 112 at 189 ℓ/min, hydraulic cooling gear pump SAL (3) 80 at 94 ℓ/min, and EPC and brake gear pump SAR (1) 28 at 54 ℓ/min. Work-equipment set pressure is 34.3 MPa {350 kg/cm²} on the 3-spool valve with HI valve; steering set pressure is 24.5 MPa {250 kg/cm²}. Lift cylinders are two double-acting 160 x 898 mm units; the bucket cylinder is one 185 x 675 mm unit; steering cylinders are two 100 x 486 mm units. Fan motor is fixed-displacement LMF40. Work equipment uses a single link and a straight bolt-on cutting edge.

Fluid capacities in the fuel, coolant and lubricant table are engine oil pan 45 ℓ specified (refill 45 ℓ, 37 ℓ for the pan alone), transmission case 95 ℓ specified / 76 ℓ refill, hydraulic system 460 ℓ specified / 337 ℓ refill, front axle 95 ℓ, rear axle 95 ℓ, cooling system 120 ℓ, and fuel tank 473 ℓ. Recommended fluids include Komatsu engine oils EOS0W30, EOS5W40, EO10W30-DH, EO15W40-DH and EO30-DH, power-train oil TO10, hydraulic oil HO46-HM, axle oil AXO80, greases G2-T / G2-TE / G2-LI, Supercoolant AF-NAC, and ASTM Grade No.1-D / No.2-D S15 and S500 diesel fuels by temperature band.

Chapters Covered

• 00 Index and foreword — composition of shop manual; table of contents; safety notice; how to read the shop manual; maintenance-standard terms; handling of electric and hydraulic components; engine connectors; electric wire code; operation precautions; push-pull coupler; standard tightening torque; conversion table
• 01 Specification — specification dimension drawing; specifications; weight table; table of fuel, coolant and lubricants
• 10 Structure, function and maintenance standard — engine and cooling system (cooling system, mounts, joint, cooling fan pump and motor)
• Power train, Part 1 — system diagram, drive shaft, piping, torque converter, regulator valve, transmission, transfer, control valve, ECMV, main and torque-converter relief valves, lubrication relief valve
• Power train, Part 2 — torque converter oil cooler and filter, center support, axle, differential, limited slip differential, final drive
• Steering system — piping, column, control valve, steering valve, stop valve, joystick linkage if equipped, steering cylinder, emergency steering piping and diverter valve if equipped
• Brake system — piping, brake valve, slack adjuster, accumulator charge valve, PPC relief valve, brake accumulator, wheel brake, parking brake control, parking brake, solenoid and emergency release valve
• Undercarriage and frame — axle mount, center hinge pin
• Hydraulic system, Parts 1 and 2 — piping, lever linkage, tank, steering pump, work equipment pump, control valve, CLSS, valve functions, PPC accumulator, work equipment electric lever
• Work equipment — linkage, bucket, bucket positioner and boom kick-out, lubrication, cylinders
• Cab and attachments — ROPS cab, air conditioner
• Electrical system, Parts 1–3 — machine monitor and EMMS, work equipment control, transmission controller, electric transmission control, starting/stopping/preheat, parking brake, lamps, horn, wiper, sensors, KOMTRAX
• 20 Standard value table — engine and chassis service-value tables
• 30 Testing and adjusting, Parts 1–4 — engine measurements, fuel system, belts, power-train pressures, flushing, steering, fan, brakes and accumulators, work equipment PPC and pressures, bucket positioner, KOMTRAX terminal, monitor adjustments, Pm clinic table
• 40 Troubleshooting — general method; failure codes Parts 1–10; E-mode electrical; H-mode hydraulic and mechanical; S-mode engine
• 50 Disassembly and assembly — special tools and coatings; engine and cooling; power train and axles; brakes; center hinge pin; hydraulic pumps, valves and cylinders; work equipment and counterweights; cab, glass and seat; controllers, KOMTRAX and air conditioner
• 90 Diagrams and drawings — automatic greasing, power train, brake and work-equipment hydraulic circuits; air-conditioner and machine electrical circuits; connector arrangement

Taken together, the Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-19 Serial 55001 and Up is the book a shop uses when the machine must be measured, diagnosed, adjusted, or taken apart to the component level. Structure chapters explain how each circuit and unit works and give maintenance-standard clearances. Testing chapters give tool lists, pickup points, and the numbers that belong on a new machine versus the service limit. Troubleshooting is split by displayed failure code, then by E-mode electrical symptoms, H-mode travel/steer/brake/implement complaints, and S-mode engine complaints. Disassembly chapters list slinging weights, special tools, coating materials, and reassembly torques. Section 90 supplies the hydraulic and electrical drawings needed to trace a circuit instead of guessing at hose or connector identity.

What the testing and failure-code books actually support

Testing and adjusting Part 1 covers engine speed, exhaust color and temperature, valve clearance, compression, blow-by, engine oil pressure, intake boost, residual-pressure release and fuel-pressure checks, injector return and leakage, air bleeding, reduced-cylinder mode, no-injection cranking, controller voltage cautions, alternator and A/C belt tension, transmission speed-sensor adjustment, directional-lever measurement, power-train oil pressures, torque-converter and transmission flushing, and moving the machine when a transmission valve has failed.

Part 2 continues with steering stop-valve and wheel checks, steering pressure and cylinder bleeding, hydraulic-drive fan tests and bleeding, brake pedal and stopping-distance checks, accumulator nitrogen charge, charge-pressure adjustment, wheel-brake pressure and disc wear, brake-circuit bleeding and residual-pressure release, parking-brake performance, pressure and disc wear, manual parking-brake release, work-equipment lever and PPC pressure, implement system pressure, circuit bleeding and residual-pressure release, cab-removal machine-move method on separate-cab machines, bucket positioner and lift-arm position-lever adjustment, proximity-switch lamp check, diode testing, and electrical-troubleshooting preparation.

Parts 3 and 4 cover KOMTRAX terminal start-up and indicator lamps (if equipped), monitor-based sensor and controller replacement adjustments, and the special functions of the machine monitor (EMMS), including the Pm clinic inspection table used to record serial numbers and measured values for the WA500-6 SAA6D140E-5 installation.

Failure-code books run from TORQFLOW double meshing and transmission-filter clogging through ECMV fill-signal faults on F, R, 1st, 2nd, 3rd and 4th clutches, parking-brake malfunction, front and rear accumulator low pressure, bucket-positioner disagreement, air-cleaner clogging, alternator faults, engine-oil and coolant level and temperature warnings, torque-converter and hydraulic-oil overheat, then the CA-series engine-controller codes for speed sensors, boost and oil-pressure sensors, throttle, coolant and charge-air temperature, rail pressure, injectors, PCV circuits, EGR and bypass valves, intake-air heater relay, idle validation, and battery voltage. Later parts cover monitor, transmission-controller and work-equipment-controller voltage and CAN faults, panel and FNR switches, temperature and pressure sensors, EPC lever potentiometers, lift-arm angle sensor, speed sensors, and the full set of EPC, ECMV, fan, lockup and joystick-steering solenoid open/short codes.

E-mode charts start from an engine that will not crank or start and continue through wiper, washer, lighting, working lamps, turn and hazard, brake and backup lamps, backup buzzer, horn, alarm buzzer, air conditioner, and KOMTRAX. H-mode charts cover a machine that will not start moving, lockup that will not release or engage, weak travel and shift, shift shock and lag, high converter temperature, steering that will not turn or is slow or heavy (wheel and joystick), brake drag or no brake, parking-brake faults including emergency release, lift-arm and bucket speed, drift and float, engine droop under implement load, and ECSS pitching. S-mode charts cover hard start, no start, poor pickup, stall in operation, hunting, lack of power, smoke, oil consumption and contamination, fuel use, coolant in oil, oil-pressure drop, overheat, abnormal noise, and vibration.

Disassembly coverage and lifting data

The weight table is written for slinging and transport. Dry engine weight is 1,700 kg; radiator with A/C condenser 326 kg; torque converter with drive gear 558 kg; transmission 1,106 kg; front axle 2,250 kg; rear axle 2,084 kg; hydraulic tank 412 kg; lift cylinder 282 kg each; bucket cylinder 289 kg; front frame 2,565 kg; rear frame 2,650 kg; lift arm with bushings 2,105 kg; 5.6 m³ BOC bucket 3,005 kg; counterweight 2,480 kg; cab with console 987 kg. Disassembly books then give the removal order for the engine assembly (noted around 1,900 kg when slung as a unit in the R&I text), radiator, aftercooler, cooling fan and fan motor, fuel tank, hood, supply pump, cylinder head, injectors, front and rear seals, torque converter and transmission, input transfer, lockup and lockup-less converters, transmission, transfer and parking brake, front and rear axles, differentials (LSD and LSD-less), final drives, brakes, slack adjuster, accumulator charge valve, center hinge pin, hydraulic tank and pumps, work-equipment valve, steering and lift/bucket cylinders, steering valve, work equipment, large and small counterweights, separate-cab and cab-floor-unit cabs, stuck glass, seat, and the engine, transmission, work-equipment controllers plus KOMTRAX terminal and A/C unit.

Using the Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-19 Serial 55001 and Up on the job

A technician working a WA500-6 from serial 55001 upward can use this shop manual to confirm whether a pressure, speed, or temperature is still inside the standard-value table; to charge or test brake accumulators; to set steering stops and fan speed; to bleed steering, fan, brake, and implement circuits; to interpret a displayed code such as an ECMV fill disagreement or a CA rail-pressure fault; to follow an H-mode chart when travel is weak or the parking brake will not release; and to lift major units with the published component weights and special-tool list. Correct service values and the failure-code sequence matter on this machine because the transmission ECMVs, CLSS implement system, wet brakes, and common-rail engine controller all depend on measured pressure, current, and sensor agreement rather than guesswork.

After payment you receive the Komatsu WA500-6 Wheel Loader Shop Manual SEN00236-19 Serial 55001 and Up as an instant PDF download. There is no shipped binder and no waiting on freight. Open the file on a shop PC, tablet, or phone and print the specification sheet, a failure-code page, or a circuit diagram when the machine is on the floor.