Komatsu WA500-6 Wheel Loader Shop Manual VEBM430102 – PDF DOWNLOAD 

Description

Komatsu WA500-6 Wheel Loader Shop Manual VEBM430102 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-6 Wheel Loader Shop Manual VEBM430102 – PDF DOWNLOAD 

Language : English
Pages : 1844
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA500-6 Wheel Loader Shop Manual VEBM430102 – PDF DOWNLOAD 

SERIAL NUMBERS H60051 and up

Cover 1
00 Index and foreword 3
Index 3
Foreword and general information 21
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling of electric equipment and hydraulic component 31
Handling of connectors newly used for engines 40
How to read electric wire code 43
Precautions when carrying out operation 46
Method of disassembling and connecting push-pull type coupler 49
Standard tightening torque table 52
Conversion table 56
01 Specification 61
Specification and technical data 61
Specification dimension drawing 62
Specifications 63
Weight table 66
Table of fuel, coolant and lubricants 68
10 Structure, function and maintenance standard 69
Engine and cooling system 69
Cooling system 70
Engine mount and transmission mount 73
Joint 74
Cooling fan pump 76
Cooling fan motor 83
Power train, Part 1 89
Power train 90
Power train system diagram 91
Drive shaft 93
Power train piping diagram 96
Torque converter 98
Torque converter regulator valve 116
Transmission 118
Transfer 138
Transmission control valve 140
ECMV 146
Main relief valve and torque converter relief valve 153
Lubrication relief valve 155
Power train, Part 2 157
Torque converter oil cooler 158
Torque converter oil filter 159
Center support 162
Axle 164
Differential 166
Limited slip differential 175
Final drive 180
Steering system 185
Steering piping diagram 186
Steering column 187
Steering control valve 188
Steering valve 199
Stop valve 203
Joystick steering lever linkage (if equipped) 204
Steering cylinder 205
Emergency steering piping diagram (if equipped) 208
Diverter valve 209
Brake system 215
Brake piping diagram 216
Brake valve 218
Slack adjuster 223
Accumulator charge valve 226
PPC relief valve 230
Accumulator (for brake) 232
Brake 234
Parking brake control 237
Parking brake 238
Parking brake solenoid valve 240
Emergency parking brake release valve 242
Undercarriage and frame 243
Axle mount 244
Center hinge pin 249
Hydraulic system, Part 1 253
Hydraulic piping diagram 254
Work equipment control lever linkage 256
Hydraulic tank 257
Steering pump 259
Work equipment hydraulic pump 270
Hydraulic system, Part 2 289
Control valve 290
CLSS 304
Each function and operation of each valve 309
Accumulator (for PPC circuit) 320
Work equipment electric lever 321
Work equipment 325
Work equipment linkage 326
Bucket 330
Bucket positioner and boom kick-out 332
Work equipment lubrication 333
Work equipment cylinder 335
Cab and its attachments 337
ROPS cab 338
Air conditioner 340
Electrical system, Part 1 349
Machine monitor system 350
Machine monitor 358
Electrical system, Part 2 411
Work equipment control system 412
Transmission controller system 446
Electrical system, Part 3 479
Electric transmission control 480
Engine starting circuit 484
Engine stopping circuit 486
Preheating circuit 487
Parking brake circuit 489
Backup and stop lamp circuits 494
Small lamp and head lamp circuits 496
Working lamp circuit 497
Horn circuit 498
Wiper and window washer circuits 499
Sensor 502
KOMTRAX system 520
Central lubrication system (CLS) 523
20 Standard value table 531
Standard service value table 531
Standard service value table for engine 532
Standard service value table for chassis 533
30 Testing and adjusting 541
Testing and adjusting, Part 1 541
Tools for testing, adjusting, and troubleshooting 543
Measuring engine speed 547
Measuring exhaust gas color 549
Measuring exhaust temperature 551
Adjusting valve clearance 553
Testing compression pressure 554
Measuring blow-by pressure 556
Measuring engine oil pressure 557
Measuring intake air (boost) pressure 558
Handling fuel system equipment 560
Releasing residual pressure in fuel system 560
Testing fuel pressure 561
Testing return rate and leakage 562
Bleeding air from fuel circuit 565
Testing leakage in fuel system 567
Handling reduced cylinder mode operation 568
Handling no injection cranking operation 568
Handling controller voltage circuit 569
Testing and adjusting alternator belt tension 570
Testing and adjusting air conditioner compressor belt tension 571
Adjusting transmission speed sensor 572
Measuring directional lever (Steering wheel specification) 574
Testing and adjusting power train oil pressure 575
Flushing procedure for torque converter and transmission hydraulic circuit 588
Method of moving machine when transmission valve is broken 591
Testing and adjusting, Part 2 593
Testing and adjusting steering stop valve 595
Testing and adjusting steering wheel 597
Testing steering oil pressure 599
Bleeding air from steering cylinder circuit 602
Testing hydraulic drive fan 603
Bleeding air from hydraulic drive fan circuit 606
Measuring brake pedal 608
Measuring brake performance 609
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 610
Testing and adjusting accumulator charge pressure 615
Testing wheel brake oil pressure 617
Measuring wear of wheel brake disc 619
Bleeding air from brake circuit 620
Releasing residual pressure in brake accumulator circuit 622
Testing parking brake performance 623
Measuring parking brake oil pressure 624
Testing wear of parking brake disc 627
Method of releasing parking brake manually 628
Measuring and adjusting work equipment control lever 629
Testing and adjusting work equipment PPC oil pressure 630
Measuring work equipment oil pressure 632
Bleeding air from work equipment circuit 638
Releasing residual pressure in work equipment circuit 639
Method of moving machine when removing operator cab (when separate cab and floor specification) 640
Testing and adjusting bucket positioner 641
Testing and adjusting lift arm position detecting lever 643
Checking proximity switch operation indication lamp 644
Procedure for testing diodes 645
Preparations for work on troubleshooting of electrical system 646
Testing and adjusting, Part 3 649
How to start KOMTRAX terminal operations 650
Indicator lamps of KOMTRAX terminal 655
Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller 658
Special functions of machine monitor (EMMS) 660
Testing and adjusting, Part 4 701
Special functions of machine monitor (EMMS) 702
Pm clinic inspection table 740
40 Troubleshooting 743
General information on troubleshooting 743
Points to remember when troubleshooting 744
Sequence of events in troubleshooting 745
Testing before troubleshooting 746
Classification and procedures of troubleshooting 747
Connection table for connector pin numbers 750
T- branch box and T- branch adapter table 786
Troubleshooting by failure code (Display of code), Part 1 789
Failure codes list 791
Before carrying out troubleshooting for electrical system 802
Information contained in troubleshooting table 804
Failure code [1500L0] (TORQFLOW transmission : Double meshing) 806
Failure code [15B0NX] (Transmission filter: Clogged) 808
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 810
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 812
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 814
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 816
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 818
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 820
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 822
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 824
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 826
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 828
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 830
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 832
Failure code [2F00MA] (Parking brake: Malfunction) 834
Failure code [2G42ZG] (Front accumulator: Low oil pressure) 836
Troubleshooting by failure code (Display of code), Part 2 839
Failure code [2G43ZG] (Rear accumulator: Low oil pressure) 842
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 844
Failure code [AA1ANX] (Air cleaner: Clogging) 846
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 848
Failure code [AB00MA] (Alternator: Malfunction) 850
Failure code [B@BAZG] (Low engine oil pressure) 852
Failure code [B@BAZK] (Engine oil: Low level) 854
Failure code [B@BCNS] (Coolant: Overheating) 856
Failure code [B@BCZK] (Coolant: Low level) 858
Failure code [B@C7NS] (Brake oil: Overheating) 860
Failure code [b@CENS] (Torque converter oil: Overheating) 862
Failure code [B@CENS] (Torque converter oil: Overheating) 864
Failure code [B@GAZK] (Battery electrolyte: Low level) 866
Failure code [B@HANS] (Hydraulic oil: Overheating) 868
Failure code [CA111] (Abnormality in engine controller) 870
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 873
Failure code [CA122] (Charge pressure sensor high error) 874
Failure code [CA123] (Charge pressure sensor low error) 876
Failure code [CA131] (Throttle sensor high error) 877
Failure code [CA132] (Throttle sensor low error) 879
Failure code [CA135] (Engine oil pressure sensor high error) 880
Failure code [CA141] (Engine oil pressure sensor low error) 882
Failure code [CA144] (Coolant temperature sensor high error) 883
Failure code [CA145] (Coolant temperature sensor low error) 885
Failure code [CA153] (Charge temperature sensor high error) 886
Failure code [CA154] (Charge temperature sensor low error) 888
Failure code [CA187] (Sensor power supply 2 low error) 888
Failure code [CA221] (Atmospheric pressure sensor high error) 889
Failure code [CA222] (Atmospheric pressure sensor low error) 891
Failure code [CA227] (Sensor power supply 2 high error) 892
Troubleshooting by failure code (Display of code), Part 3 895
Failure code [CA234] (Engine overspeed) 897
Failure code [CA238] (Ne speed sensor power supply error) 898
Failure code [CA263] (Fuel temperature sensor high error) 900
Failure code [CA265] (Fuel temperature sensor low error) 902
Failure code [CA271] (PCV1 Short circuit) 904
Failure code [CA272] (PCV1 Disconnection) 906
Failure code [CA273] (PCV2 Short circuit) 908
Failure code [CA274] (PCV2 Disconnection) 910
Failure code [CA322] (Injector #1 (L/B #1) open/short error) 912
Failure code [CA323] (Injector #5 (L/B #5) open/short error) 914
Failure code [CA324] (Injector #3 (L/B #3) open/short error) 916
Failure code [CA325] (Injector #6 (L/B #6) open/short error) 918
Failure code [CA331] (Injector #2 (L/B #2) open/short error) 920
Failure code [CA332] (Injector #4 (L/B #4) open/short error) 922
Failure code [CA342] (Calibration code inconsistency) 924
Failure code [CA351] (Injector drive circuit error) 925
Failure code [CA352] (Sensor power supply 1 low error) 928
Failure code [CA386] (Sensor power supply 1 high error) 930
Failure code [CA431] (Idle validation switch error) 932
Failure code [CA432] (Idle validation action error) 934
Failure code [CA441] (Battery voltage low error) 934
Failure code [CA442] (Battery voltage high error) 935
Failure code [CA449] Common rail pressure high error 2 935
Failure code [CA451] (Common rail pressure sensor high error) 936
Failure code [CA452] (Common rail pressure sensor low error) 938
Failure code [CA553] (Common rail pressure high error 1) 939
Failure code [CA554] (Common rail pressure sensor in-range error) 940
Failure code [CA559] (Supply pump pressure very low error) 941
Failure code [CA689] (Engine Ne speed sensor error) 944
Failure code [CA731] (Engine Bkup speed sensor phase error) 946
Failure code [CA757] (All continuous data lost error) 946
Failure code [CA778] (Engine Bkup speed sensor error) 948
Failure code [CA1228] (EGR valve servo error 1) 950
Failure code [CA1625] (EGR valve servo error 2) 951
Failure code [CA1626] (Bypass valve solenoid current high error) 952
Failure code [CA1627] (Bypass valve solenoid current low error) 954
Failure code [CA1628] (Bypass valve servo error 1) 955
Failure code [CA1629] (Bypass valve servo error 2) 956
Failure code [CA1631] (Bypass valve lift sensor high error) 957
Failure code [CA1632] (Bypass valve lift sensor low error) 959
Failure code [CA1633] (KOMNET datalink timeout error) 959
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor 961
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor 962
Troubleshooting by failure code (Display of code), Part 4 965
Failure code [CA1642] (EGR inlet pressure sensor low error) 967
Failure code [CA1653] (EGR inlet pressure sensor high error) 968
Failure code [CA2185] (Throttle sensor supply voltage high error) 970
Failure code [CA2186] (Throttle sensor power supply low error) 972
Failure code [CA2249] (Supply pump pressure very low error 2) 972
Failure code [CA2271] (EGR valve lift sensor high error) 973
Failure code [CA2272] (EGR valve lift sensor low error) 975
Failure code [CA2351] (EGR valve solenoid operation short circuit) 976
Failure code [CA2352] (EGR valve solenoid operation disconnect) 978
Failure code [CA2555] (Intake heater relay disconnection error) 978
Failure code [CA2556] (Intake heater relay short circuit error) 980
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit) 982
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 984
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 986
Failure code [D192KA] (ECSS solenoid: Disconnection) 988
Failure code [D192KB] (ECSS solenoid: Short circuit) 989
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 990
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 992
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 994
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) 996
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 998
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 1000
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 1002
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) 1006
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 1008
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) 1010
Failure code [DAF5KP] (Machine monitor: Low output voltage) 1012
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)) 1014
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 1016
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) 1018
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)) 1020
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals) 1022
Troubleshooting by failure code (Display of code), Part 5 1023
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)) 1026
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) 1028
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system) 1030
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 1032
Failure code [DB90KT] (Work equipment controller: Abnormality in controller) 1034
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) 1036
Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range) 1038
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals) 1040
Failure code [DB9RKR] (CAN communication with work equipment controller: Defective communication (Abnormality in target component system)) 1042
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) 1044
Failure code [DB9RMC] (CAN communication with work equipment controller: Defective operation) 1046
Failure code [DD15LD] (t switch (Panel switch 1): Switch is kept pressed for long time) 1048
Failure code [DD16LD] (U switch (Panel switch 2): Switch is kept pressed for long time) 1050
Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time) 1052
Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time) 1054
Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time) 1056
Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time) 1058
Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time) 1060
Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept pressed for long time) 1062
Failure code [DD1GLD] (Load meter mode selector switch (+/–): Switch is kept pressed for long time) 1064
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) 1066
Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree) 1068
Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit) 1070
Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit) 1072
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) 1074
Troubleshooting by failure code (Display of code), Part 6 1077
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time) 1080
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) 1082
Failure code [DDK3KA] (Right FNR switch: Disconnection) 1084
Failure code [DDK3KB] (Right FNR switch: Short circuit) 1086
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1088
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) 1090
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) 1092
Failure code [DDK6KA] (FNR lever switch: Disconnection) 1094
Failure code [DDK6KB] (FNR lever switch: Short circuit) 1098
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 1100
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 1102
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 1104
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) 1106
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) 1108
Failure code [DF10KA] (Transmission shift lever switch: Disconnection) 1110
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1114
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) 1116
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) 1118
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 1120
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) 1122
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) 1124
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 1126
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) 1128
Troubleshooting by failure code (Display of code), Part 7 1131
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) 1134
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 1136
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) 1138
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) 1140
Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine) 1142
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 1144
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) 1148
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) 1151
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 1154
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) 1157
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 1160
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) 1163
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) 1166
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) 1169
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) 1172
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection) 1175
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line) 1177
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree) 1179
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection) 1182
Troubleshooting by failure code (Display of code), Part 8 1185
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line) 1188
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) 1190
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) 1192
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) 1194
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line) 1196
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) 1198
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1202
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) 1204
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 1206
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 1208
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) 1210
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree) 1212
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit) 1214
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range) 1216
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) 1218
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) 1220
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 1222
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1224
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1226
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1227
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 1228
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1230
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1231
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) 1232
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1234
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1236
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) 1238
Troubleshooting by failure code (Display of code), Part 9 1241
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1243
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1244
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) 1246
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1248
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1250
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) 1252
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) 1254
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) 1254
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) 1255
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 1256
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 1258
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) 1260
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) 1262
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) 1264
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) 1266
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) 1268
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) 1270
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) 1272
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 1274
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 1276
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 1278
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1280
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1281
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) 1282
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) 1283
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) 1284
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1285
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1286
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) 1288
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1290
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1292
Troubleshooting by failure code (Display of code), Part 10 1295
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) 1298
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1300
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1302
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) 1304
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1306
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1308
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) 1310
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1312
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1314
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) 1316
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1318
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1320
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) 1322
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1324
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1326
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) 1328
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) 1330
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit) 1331
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line) 1332
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) 1333
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) 1334
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line) 1335
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 1336
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 1338
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) 1340
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) 1342
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) 1344
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) 1346
Troubleshooting of electrical system (E-mode) 1349
Before carrying out troubleshooting of electrical system 1351
Information in troubleshooting table 1354
E-1 Engine does not start 1355
E-2 Wiper does not operate 1360
E-3 Windshield washer does not operate 1364
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off 1367
E-5 Working lamp does not light up or go off 1375
E-6 Turn signal lamp and hazard lamp do not light up or go off 1380
E-7 Brake lamp does not light or it keeps lighting up 1386
E-8 Backup lamp does not light or it keeps lighting up 1388
E-9 Backup buzzer does not sound or it keeps sounding 1390
E-10 Horn does not sound or it keeps sounding 1392
E-11 Alarm buzzer does not sound or it keeps sounding 1395
E-12 Air conditioner does not operate or stop 1397
E-13 KOMTRAX system does not work properly 1400
Troubleshooting of hydraulic and mechanical system (H-mode) 1403
Method of using troubleshooting chart 1405
Table of failure modes and causes 1408
H-1 Machine does not start 1412
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)] 1414
H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)] 1415
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted 1416
H-5 Shocks are large at the times of starting and shifting gear 1418
H-6 Time lag is large at the times of starting and shifting gear 1420
H-7 Torque converter oil temperature is high 1422
H-8 Steering does not turn 1423
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 1424
H-10 Steering response is low 1425
H-11 Turning response of steering is poor [machine with joystick steering (if equipped)] 1426
H-12 Steering is heavy 1427
H-13 When machine turns, it shakes or makes large shocks 1428
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] 1429
H-15 Wheel brake does not work or does not work well 1430
H-16 Wheel brake is not released or it drags 1431
H-17 Parking brake does not work or does not work well 1432
H-18 Parking brake is not released or it drags (including emergency release system) 1433
H-19 Lift arm does not rise 1434
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1435
H-21 When rising, lift arm comes to move slowly at specific height 1436
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) 1436
H-23 Hydraulic drifts of lift arm occur often 1436
H-24 Lift arm wobbles during operation 1436
H-25 Bucket does not tilt back 1437
H-26 Bucket speed is low or tilting back force is insufficient 1438
H-27 Bucket comes to operate slowly in the midst of tilting-back 1439
H-28 Bucket cylinder cannot hold down the bucket 1439
H-29 Hydraulic drifts of bucket occur often 1439
H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”) 1439
H-31 During operation of machine, engine speed lowers remarkably or engine stalls 1440
H-32 Large shocks are made when work equipment starts and stops 1440
H-33 When work equipment circuit is relieved singly, other work equipment moves 1440
H-34 ECSS does not operate, and pitching and bouncing occur 1441
Troubleshooting of engine (S-mode) 1443
Method of using troubleshooting chart 1445
S-1 Engine does not start easily 1448
S-2 Engine does not start 1450
S-3 Engine does not pick up smoothly 1454
S-4 Engine stops during operation 1455
S-5 Engine does not rotate smoothly (Engine hunts ) 1456
S-6 Engine lacks output (or lacks power) 1457
S-7 Exhaust smoke is black (Incomplete combustion) 1458
S-8 Oil is consumed much (or exhaust gas color is blue) 1460
S-9 Engine oil becomes contaminated quickly 1461
S-10 Fuel consumption is excessive 1462
S-11 Coolant contains oil (blows back or reduces) 1463
S-12 Oil pressure drops 1464
S-13 Oil level rises (Water, fuel in oil) 1465
S-14 Coolant temperature rises too high (Overheating) 1467
S-15 Abnormal noise is made 1468
S-16 Vibration is excessive 1469
Troubleshooting of Central Lubrication System (CLS) 1471
Trouble 1472
Troubleshooting FPS 1473
Troubleshooting 1474
Pump Faults 1474
Replace pump element 1476
Check power supply 1476
Changing the control unit: 1476
Troubleshooting – grease system faults 1477
Venting of the system 1478
General assembly advice 1479
50 Disassembly and assembly 1481
General information on disassembly and assembly 1481
How to read this manual 1482
Coating materials list 1484
Special tool list 1487
Sketches of special tools 1491
Engine and cooling system, Part 1 1499
Removal and installation of engine assembly 1500
Removal and installation of radiator assembly 1505
Removal and installation of air aftercooler 1507
Removal and installation of cooling fan and fan motor assembly 1508
Removal and installation of radiator guard and cooling fan motor assembly 1510
Removal and installation of fuel tank assembly 1513
Removal and installation of hood 1515
Engine and cooling system, Part 2 1519
Removal and installation of fuel supply pump assembly 1520
Removal and installation of cylinder head assembly 1524
Removal and installation of fuel injector assembly 1535
Removal and installation of engine front seal 1538
Removal and installation of engine rear seal 1542
Power train, Part 1 1547
Removal and installation of torque converter and transmission assembly 1548
Disconnection and connection of power train unit 1554
Disassembly and assembly of input transfer assembly 1558
Disassembly and assembly of torque converter assembly (Lockup specification) 1565
Disassembly and assembly of torque converter assembly (Lockup-less specification) 1578
Power train, Part 2 1589
Disassembly and assembly of transmission assembly 1590
Disassembly and assembly of transfer and parking brake assembly 1620
Removal and installation of front axle assembly 1636
Removal and installation of rear axle assembly 1638
Power train, Part 3 1641
Removal and installation of front differential assembly 1642
Disassembly and assembly of differential assembly (LSD specification) 1644
Disassembly and assembly of differential assembly (LSD-less specification) 1658
Disassembly and assembly of final drive assembly (Front and rear) 1670
Brake system 1677
Removal and installation of brake assembly (Front and rear) 1678
Disassembly and assembly of brake assembly (Front and rear) 1680
Disassembly and assembly of slack adjuster assembly 1686
Disassembly and assembly of brake accumulator charge valve assembly 1687
Undercarriage and frame 1689
Removal and installation of center hinge pin 1690
Hydraulic system 1697
Removal and installation of hydraulic tank assembly 1698
Removal and installation of cooling pump assembly 1701
Removal and installation of fan pump assembly 1702
Removal and installation of work equipment pump assembly 1703
Removal and installation of steering, torque converter charge and EPC pump assembly 1705
Removal and installation of work equipment valve assembly 1706
Disassembly and assembly of work equipment control valve assembly 1709
Disassembly and assembly of steering cylinder assembly 1712
Disassembly and assembly of lift arm and/bucket cylinder assembly 1716
Removal and installation of steering valve assembly 1722
Work equipment 1723
Removal and installation of work equipment assembly 1724
Removal and installation of large counterweight assembly 1728
Removal and installation of small counterweight assembly 1729
Cab and its attachments 1731
Removal and installation of operator’s cab assembly (Separate cab and floor specification) 1732
Removal and installation of operator’s cab and floor frame assembly (Cab-floor unit specification) 1737
Removal and installation of operator’s cab glass (Stuck glass) 1741
Disassembly and assembly of operator’s seat assembly 1750
Electrical system 1785
Removal and installation of engine controller assembly 1786
Removal and installation of transmission controller assembly 1787
Removal and installation of work equipment controller assembly 1788
Removal and installation of KOMTRAX terminal assembly 1789
Removal and installation of air conditioner unit assembly 1790
90 Diagrams and drawings 1795
Hydraulic diagrams and drawings 1795
Automatic greasing circuit diagram 1796
Electrical diagrams and drawings 1809
Connector list and tables 1827
Connector list 1828

DESCRIPTION:

Komatsu WA500-6 Wheel Loader Shop Manual VEBM430102 – PDF DOWNLOAD 

SERIAL NUMBERS H60051 and up

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

S.V 28/12/24