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KOMATSU WA500-6R WHEEL LOADER SHOP MANUAL SEN02876-16 – PDF DOWNLOAD
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Description
KOMATSU WA500-6R WHEEL LOADER SHOP MANUAL SEN02876-16 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA500-6R WHEEL LOADER SHOP MANUAL SEN02876-16 – PDF DOWNLOAD
Language : English
Pages : 1928
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA500-6R WHEEL LOADER SHOP MANUAL SEN02876-16 – PDF DOWNLOAD
Cover............................................................................................................................................ 1 00 Index and foreword............................................................................................................................ 3 Index........................................................................................................................................ 3 Composition of shop manual............................................................................................................... 4 Table of contents........................................................................................................................ 6 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................................................................................................................................. 63 Specification and technical data............................................................................................................. 63 Specification dimension drawing.......................................................................................................... 64 Specifications........................................................................................................................... 65 Weight table............................................................................................................................. 68 Table of fuel, coolant and lubricants.................................................................................................... 70 10 Structure, function and maintenance standard.................................................................................................. 73 Engine and cooling system.................................................................................................................... 73 Cooling system........................................................................................................................... 74 Engine mount and transmission mount...................................................................................................... 77 Power train, Part 1.......................................................................................................................... 79 Power train.............................................................................................................................. 80 Power train system diagram............................................................................................................... 81 Joint.................................................................................................................................... 83 Drive shaft.............................................................................................................................. 84 Power train piping diagram............................................................................................................... 85 Torque converter......................................................................................................................... 86 Torque converter regulator valve......................................................................................................... 104 Transmission............................................................................................................................. 106 Transfer................................................................................................................................. 126 Transmission control valve............................................................................................................... 128 ECMV..................................................................................................................................... 132 Main relief valve and torque converter relief valve...................................................................................... 139 Lubrication relief valve................................................................................................................. 141 Power train, Part 2.......................................................................................................................... 143 Torque converter oil cooler.............................................................................................................. 144 Torque converter oil filter.............................................................................................................. 145 Center support........................................................................................................................... 148 Axle..................................................................................................................................... 150 Differential............................................................................................................................. 152 Limited slip differential................................................................................................................ 161 Final drive.............................................................................................................................. 166 Steering system.............................................................................................................................. 171 Steering piping diagram.................................................................................................................. 172 Steering column.......................................................................................................................... 173 Steering control valve................................................................................................................... 174 Steering valve........................................................................................................................... 185 Stop valve............................................................................................................................... 189 Joystick steering lever linkage (if equipped)............................................................................................ 190 Steering cylinder........................................................................................................................ 191 Emergency steering piping diagram (if equipped).......................................................................................... 194 Diverter valve........................................................................................................................... 195 Brake system................................................................................................................................. 201 Brake piping diagram..................................................................................................................... 202 Brake valve.............................................................................................................................. 204 Slack adjuster........................................................................................................................... 209 Accumulator charge valve................................................................................................................. 212 PPC relief valve......................................................................................................................... 216 Accumulator (for brake).................................................................................................................. 218 Brake.................................................................................................................................... 220 Parking brake control.................................................................................................................... 223 Parking brake............................................................................................................................ 224 Parking brake solenoid valve............................................................................................................. 226 Emergency parking brake release valve.................................................................................................... 228 Undercarriage and frame...................................................................................................................... 231 Axle mount............................................................................................................................... 232 Center hinge pin......................................................................................................................... 237 Hydraulic system, Part 1..................................................................................................................... 241 Hydraulic piping diagram................................................................................................................. 242 Work equipment control lever linkage..................................................................................................... 244 Hydraulic tank........................................................................................................................... 245 Cooling fan motor........................................................................................................................ 247 Cooling fan pump......................................................................................................................... 254 Steering pump............................................................................................................................ 261 Work equipment hydraulic pump............................................................................................................ 272 Hydraulic system, Part 2..................................................................................................................... 293 Control valve............................................................................................................................ 294 CLSS..................................................................................................................................... 308 Each function and operation of each valve................................................................................................ 313 Accumulator (for PPC circuit)............................................................................................................ 324 Work equipment electric lever............................................................................................................ 325 Work equipment............................................................................................................................... 329 Work equipment linkage................................................................................................................... 330 Bucket................................................................................................................................... 334 Bucket positioner and boom kick-out...................................................................................................... 336 Work equipment lubrication............................................................................................................... 337 Cab and its attachments...................................................................................................................... 341 ROPS cab................................................................................................................................. 342 Air conditioner.......................................................................................................................... 344 Electrical system, Part 1.................................................................................................................... 353 Machine monitor system................................................................................................................... 354 Machine monitor.......................................................................................................................... 362 Electrical system, Part 2.................................................................................................................... 417 Work equipment control system............................................................................................................ 418 Transmission controller system........................................................................................................... 452 Electrical system, Part 3.................................................................................................................... 485 Electric transmission control............................................................................................................ 486 Engine starting circuit.................................................................................................................. 490 Engine stopping circuit.................................................................................................................. 492 Preheating circuit....................................................................................................................... 493 Parking brake circuit.................................................................................................................... 495 Backup and stop lamp circuits............................................................................................................ 500 Small lamp and head lamp circuits........................................................................................................ 502 Working lamp circuit..................................................................................................................... 503 Horn circuit............................................................................................................................. 504 Wiper and window washer circuits......................................................................................................... 505 Sensor................................................................................................................................... 508 KOMTRAX terminal system (if equipped).................................................................................................... 526 20 Standard value table.......................................................................................................................... 529 Standard service value table................................................................................................................. 529 Standard service value table for engine.................................................................................................. 530 Standard service value table for chassis................................................................................................. 531 30 Testing and adjusting......................................................................................................................... 541 Testing and adjusting, Part 1................................................................................................................ 541 Tools for testing, adjusting, and troubleshooting........................................................................................ 543 Measuring engine speed................................................................................................................... 550 Measuring exhaust gas color.............................................................................................................. 552 Measuring exhaust temperature............................................................................................................ 554 Adjusting valve clearance................................................................................................................ 556 Testing compression pressure............................................................................................................. 557 Measuring blow-by pressure............................................................................................................... 559 Measuring engine oil pressure............................................................................................................ 560 Measuring intake air (boost) pressure.................................................................................................... 561 Handling fuel system equipment........................................................................................................... 563 Releasing residual pressure in fuel system............................................................................................... 563 Testing fuel pressure.................................................................................................................... 564 Testing return rate and leakage.......................................................................................................... 565 Bleeding air from fuel circuit........................................................................................................... 568 Testing leakage in fuel system........................................................................................................... 570 Handling reduced cylinder mode operation................................................................................................. 571 Handling no injection cranking operation................................................................................................. 571 Handling controller voltage circuit...................................................................................................... 572 Testing and adjusting alternator belt tension............................................................................................ 573 Testing and adjusting air conditioner compressor belt tension............................................................................ 574 Adjusting transmission speed sensor...................................................................................................... 575 Measuring directional lever (Steering wheel specification)............................................................................... 577 Testing and adjusting power train oil pressure........................................................................................... 578 Flushing procedure for torque converter and transmission hydraulic circuit............................................................... 591 Method of moving machine when transmission valve is broken............................................................................... 594 Testing and adjusting, Part 2................................................................................................................ 597 Testing and adjusting steering stop valve................................................................................................ 599 Testing and adjusting steering wheel..................................................................................................... 601 Testing steering oil pressure............................................................................................................ 603 Bleeding air from steering cylinder circuit.............................................................................................. 606 Testing hydraulic drive fan.............................................................................................................. 607 Bleeding air from hydraulic drive fan circuit............................................................................................ 610 Measuring brake pedal.................................................................................................................... 612 Measuring brake performance.............................................................................................................. 613 Testing and charging accumulator nitrogen gas pressure for brake......................................................................... 614 Testing ECSS accumulator nitrogen gas pressure and charging accumulator with nitrogen gas................................................ 620 Testing and adjusting accumulator charge pressure........................................................................................ 627 Testing wheel brake oil pressure......................................................................................................... 629 Measuring wear of wheel brake disc....................................................................................................... 631 Bleeding air from brake circuit.......................................................................................................... 632 Releasing residual pressure in brake accumulator circuit................................................................................. 634 Testing parking brake performance........................................................................................................ 635 Measuring parking brake oil pressure..................................................................................................... 636 Testing wear of parking brake disc....................................................................................................... 639 Method of releasing parking brake manually............................................................................................... 640 Measuring and adjusting work equipment control lever..................................................................................... 641 Testing and adjusting work equipment PPC oil pressure.................................................................................... 642 Measuring work equipment oil pressure.................................................................................................... 644 Bleeding air from work equipment circuit................................................................................................. 650 Releasing residual pressure in work equipment circuit.................................................................................... 651 Method of moving machine when removing operator cab (when splittable cab is used)........................................................ 652 Testing and adjusting bucket positioner.................................................................................................. 653 Testing and adjusting lift arm position detecting lever.................................................................................. 655 Checking proximity switch operation indication lamp...................................................................................... 656 Procedure for testing diodes............................................................................................................. 657 Preparations for work on troubleshooting of electrical system............................................................................ 658 Testing and adjusting, Part 3................................................................................................................ 663 Starting KOMTRAX terminal operations..................................................................................................... 664 Indicator lamps of KOMTRAX terminal...................................................................................................... 670 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller.... 673 Special functions of machine monitor (EMMS).............................................................................................. 675 Testing and adjusting, Part 4................................................................................................................ 715 Special functions of machine monitor (EMMS).............................................................................................. 716 Pm clinic inspection table............................................................................................................... 754 40 Troubleshooting............................................................................................................................... 759 Failure codes list and fuse locations........................................................................................................ 759 Failure codes list....................................................................................................................... 760 Fuse locations........................................................................................................................... 771 General information on troubleshooting....................................................................................................... 775 Points to remember when performing troubleshooting....................................................................................... 776 How to proceed in troubleshooting........................................................................................................ 778 Testing before troubleshooting........................................................................................................... 780 Classification and procedures of troubleshooting......................................................................................... 781 Information in troubleshooting table..................................................................................................... 785 Troubleshooting method for disconnecting wiring harness of pressure sensor system........................................................ 787 Phenomena looking like troubles and troubleshooting Nos.................................................................................. 790 Connection table for connector pin numbers............................................................................................... 792 T- branch box and T- branch adapter table................................................................................................ 828 Troubleshooting by failure code (Display of code), Part 1.................................................................................... 833 Failure code [1500L0] (TORQFLOW transmission : Double meshing)........................................................................... 835 Failure code [15B0NX] (Transmission filter: Clogged)..................................................................................... 836 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON).................................................... 838 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF).................................................... 840 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON).................................................... 842 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF).................................................... 844 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).................................................. 846 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).................................................. 848 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).................................................. 850 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF).................................................. 852 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).................................................. 854 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF).................................................. 856 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).................................................. 858 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF).................................................. 860 Failure code [2F00MA] (Parking brake: Malfunction)....................................................................................... 862 Failure code [2G42ZG] (Front accumulator: Low oil pressure).............................................................................. 864 Troubleshooting by failure code (Display of code), Part 2.................................................................................... 867 Failure code [2G43ZG] Rear accumulator: Low oil pressure................................................................................. 870 Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree......................................................................... 872 Failure code [AA1ANX] Air cleaner: Clogging.............................................................................................. 876 Failure code [AB00L6] Alternator: Signal disagrees with operating state of engine........................................................ 878 Failure code [AB00MA] Alternator: Malfunction............................................................................................ 880 Failure code [B@BAZG] Low engine oil pressure............................................................................................ 882 Failure code [B@BAZK] Engine oil: Low level.............................................................................................. 884 Failure code [B@BCNS] Coolant: Overheating............................................................................................... 886 Failure code [B@BCZK] Coolant: Low level................................................................................................. 888 Failure code [b@CENS] Torque converter oil: Overheating.................................................................................. 890 Failure code [B@CENS] Torque converter oil: Overheating.................................................................................. 891 Failure code [B@GAZK] Battery electrolyte: Low level..................................................................................... 892 Failure code [B@HANS] Hydraulic oil: Overheating......................................................................................... 893 Failure code [CA111] Abnormality in engine controller.................................................................................... 894 Failure code [CA115] Engine Ne or Bkup speed sensor error................................................................................ 897 Failure code [CA122] Charge (boost) pressure sensor high error........................................................................... 898 Failure code [CA123] Charge (boost) pressure sensor low error............................................................................ 900 Failure code [CA131] Throttle sensor high error.......................................................................................... 902 Failure code [CA132] Throttle sensor low error........................................................................................... 905 Failure code [CA135] Engine oil pressure sensor high error............................................................................... 908 Failure code [CA141] Engine oil pressure sensor low error................................................................................ 910 Failure code [CA144] Coolant temperature sensor high error............................................................................... 912 Failure code [CA145] Coolant temperature sensor low error................................................................................ 914 Failure code [CA153] Charge (boost) temperature sensor high error........................................................................ 916 Failure code [CA154] Charge (boost) temperature sensor low error......................................................................... 918 Failure code [CA187] Sensor power supply 2 low error..................................................................................... 920 Failure code [CA221] Atmospheric pressure sensor high error.............................................................................. 922 Failure code [CA222] Atmospheric pressure sensor low error............................................................................... 924 Failure code [CA227] Sensor power supply 2 high error.................................................................................... 926 Troubleshooting by failure code (Display of code), Part 3.................................................................................... 929 Failure code [CA234] Engine overspeed.................................................................................................... 931 Failure code [CA238] Ne speed sensor power supply error.................................................................................. 932 Failure code [CA263] Fuel Temp Sensor High Error......................................................................................... 934 Failure code [CA265] Fuel Temp Sensor Low Error.......................................................................................... 936 Failure code [CA271] PCV1 Short circuit.................................................................................................. 938 Failure code [CA272] PCV1 Disconnection.................................................................................................. 939 Failure code [CA273] PCV2 Short circuit.................................................................................................. 940 Failure code [CA274] PCV2 Disconnection.................................................................................................. 941 Failure code [CA322] Injector #1 open/short error........................................................................................ 942 Failure code [CA323] Injector #5 open/short error........................................................................................ 944 Failure code [CA324] Injector #3 open/short error........................................................................................ 946 Failure code [CA325] Injector #6 open/short error........................................................................................ 948 Failure code [CA331] Injector #2 open/short error........................................................................................ 950 Failure code [CA332] Injector #4 open/short error........................................................................................ 952 Failure code [CA342] Calibration code inconsistency...................................................................................... 954 Failure code [CA351] Injectors drive circuit error....................................................................................... 955 Failure code [CA352] Sens Supply 1 Volt Low Error........................................................................................ 956 Failure code [CA386] Sensor power supply 1 high error.................................................................................... 958 Failure code [CA431] Idle validation switch error........................................................................................ 959 Failure code [CA432] Idle validation action error........................................................................................ 962 Failure code [CA441] Battery voltage low error........................................................................................... 964 Failure code [CA442] Battery voltage high error.......................................................................................... 965 Failure code [CA449] Common rail pressure high error 2................................................................................... 966 Failure code [CA451] Rail Press Sensor High Error........................................................................................ 968 Failure code [CA452] Rail Press Sensor Low Error......................................................................................... 970 Failure code [CA553] Common rail pressure high error 1................................................................................... 972 Failure code [CA554] Common rail pressure sensor in range error.......................................................................... 973 Failure code [CA559] Supply pump pressure very low error 1............................................................................... 974 Failure code [CA689] Engine Ne speed sensor error........................................................................................ 978 Failure code [CA731] Engine Bkup speed sensor phase error................................................................................ 980 Failure code [CA757] All continuous data lost error...................................................................................... 981 Failure code [CA778] Engine Bkup speed sensor error...................................................................................... 982 Failure code [CA1633] KOMNET datalink timeout error...................................................................................... 984 Troubleshooting by failure code (Display of code), Part 4.................................................................................... 987 Failure code [CA2185] Throttle sensor supply voltage high error.......................................................................... 990 Failure code [CA2186] Throttle sensor power supply low error............................................................................. 992 Failure code [CA2249] Supply pump pressure very low error 2.............................................................................. 994 Failure code [CA2555] Intake air heater relay open circuit error......................................................................... 996 Failure code [CA2556] Intake air heater relay short circuit error........................................................................ 998 Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit..................................................................1000 Failure code [D191KA] Joystick steering neutral safety relay: Disconnection..............................................................1002 Failure code [D191KB] Joystick steering neutral safety relay: Short circuit..............................................................1004 Failure code [D192KA] ECSS solenoid: Disconnection.......................................................................................1006 Failure code [D192KB] ECSS solenoid: Short circuit.......................................................................................1007 Failure code [D192KY] ECSS solenoid: Short circuit with power supply line................................................................1008 Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection................................................................1010 Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit................................................................1012 Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit with power supply line.........................................1014 Failure code [D5ZHKA] Terminal C signal: Disconnection...................................................................................1016 Failure code [D5ZHKB] Terminal C signal: Short circuit...................................................................................1020 Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit..................................................................1022 Failure code [D5ZHL6] Terminal C signal: Signal does not match engine running or stopped state...........................................1024 Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree....................................................................1027 Failure code [DAF3KK] Machine monitor: Low source voltage (input)........................................................................1030 Failure code [DAF5KP] Machine monitor: Low output voltage................................................................................1032 Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in target component system)...............1034 Failure code [DAQ0KK] Transmission controller: Low source voltage........................................................................1035 Failure code [DAQ0KT] Transmission controller: Abnormality in controller.................................................................1038 Failure code [DAQ2KK] Transmission controller load power supply line: Low source voltage (input).........................................1039 Failure code [DAQ9KQ] Transmission controller model selection: Disagreement of model selection signals...................................1042 Troubleshooting by failure code (Display of code), Part 5....................................................................................1045 Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality in target component system).......1047 Failure code [DAQRMA] Transmission controller option setting: Malfunction................................................................1052 Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in target component system).............1054 Failure code [DB90KK] Work equipment controller: Low source voltage (input)..............................................................1059 Failure code [DB90KT] Work equipment controller: Abnormality in controller...............................................................1062 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input).......................................1063 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...........................................1066 Failure code [DB99KQ] Work equipment controller model selection: Disagreement of model selection signals.................................1068 Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system).....1069 Failure code [DB9RMA] Work equipment controller option setting: Malfunction..............................................................1070 Failure code [DB9RMC] CAN communication with work equipment controller: Defective operation..............................................1071 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time....................................................1072 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time....................................................1074 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time....................................................1076 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time....................................................1078 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time.............................1080 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time.............................1082 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...................................................1084 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time........................................1086 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time........................................1088 Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time...........................................1090 Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree.....................................................................1092 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit......................................................1094 Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit....................................................1097 Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree........................................................1100 Troubleshooting by failure code (Display of code), Part 6....................................................................................1105 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)..................................1108 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction).....................................................................1110 Failure code [DDK3KA] (Right FNR switch: Disconnection)..................................................................................1112 Failure code [DDK3KB] (Right FNR switch: Short circuit)..................................................................................1114 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)......................................................................1116 Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)......................................................................1118 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)..................................................1120 Failure code [DDK6KA] (FNR lever switch: Disconnection)..................................................................................1122 Failure code [DDK6KB] (FNR lever switch: Short circuit)..................................................................................1126 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)..............................................................1128 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)............................................1130 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...........................................................1132 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)................................................................1134 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...................................................1136 Failure code [DF10KA] (Transmission shift lever switch: Disconnection)...................................................................1138 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...................................................................1142 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)...............................................................1144 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...............................................................1146 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)......................................................1148 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection).................................................................1150 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).....................................................1152 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...............................................1154 Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)...........................................................1156 Troubleshooting by failure code (Display of code), Part 7....................................................................................1159 Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)...........................................................1162 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)..............................................1164 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)................................................1166 Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range)............................................................1168 Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine)................1170 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...........................................................1172 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)....................................1175 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).................................................1178 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)............................................................1182 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).....................................1185 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).............................................................1188 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)......................................1191 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...................................................1194 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)..............................................................1198 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line).......................................1201 Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection).........................................1204 Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)..................1207 Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)...............................1209 Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)..........................................1212 Troubleshooting by failure code (Display of code), Part 8....................................................................................1217 Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)................................1220 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)..................................................1222 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...........................1224 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...................................................1226 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)............................1228 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)........................................1230 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).............................................................................1234 Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range).................................................................1236 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)......................................................1238 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)............................................................................1240 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection).............................................................1242 Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)....................................................1244 Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)............................................................1246 Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range)................................................1248 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...............................................................1250 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)........................................................1252 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)........................................................1254 Failure code [DV00KB] (Alarm buzzer: Short circuit)......................................................................................1256 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection).......................................................................1258 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit).......................................................................1259 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)................................................1260 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection).......................................................................1262 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit).......................................................................1263 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)................................................1264 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..........................................................................1266 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..........................................................................1268 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...................................................1270 Troubleshooting by failure code (Display of code), Part 9....................................................................................1273 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..........................................................................1275 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..........................................................................1276 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...................................................1278 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)..............................................................................1280 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)..............................................................................1282 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line).......................................................1284 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)..............................................................1286 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)..............................................................1286 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line).......................................1287 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)..............................................................1288 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)..............................................................1290 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line).......................................1292 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).............................................................1294 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).............................................................1296 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)......................................1298 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).............................................................1300 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).............................................................1302 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)......................................1304 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)................................................................1306 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)................................................................1308 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Short circuit with power supply line).........................................1310 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).............................................................................1312 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).............................................................................1313 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)......................................................1314 Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)..............................................................................1315 Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)..............................................................................1316 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)..............................................................................1317 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)..............................................................................1318 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line).......................................................1320 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..........................................................................1322 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..........................................................................1324 Troubleshooting by failure code (Display of code), Part 10...................................................................................1327 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...................................................1330 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..........................................................................1332 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..........................................................................1334 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...................................................1336 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..........................................................................1338 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..........................................................................1340 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...................................................1342 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)............................................................................1344 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)............................................................................1346 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).....................................................1348 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)............................................................................1350 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)............................................................................1352 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).....................................................1354 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..........................................................................1356 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..........................................................................1358 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...................................................1360 Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)................................................................1362 Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)................................................................1363 Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line).........................................1364 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)................................................................1365 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)................................................................1366 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line).........................................1367 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)..............................................................1368 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)..............................................................1370 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line).......................................1372 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...............................................................1374 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...............................................................1376 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)........................................1378 Troubleshooting of electrical system (E-mode)................................................................................................1381 Fuse locations...........................................................................................................................1383 Information in troubleshooting table.....................................................................................................1386 E-1 Engine does not start................................................................................................................1387 E-2 Wiper does not operate...............................................................................................................1392 E-3 Windshield washer does not operate...................................................................................................1396 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off......................................................1399 E-5 Working lamp does not light up or go off.............................................................................................1407 E-6 Turn signal lamp and hazard lamp do not light up or go off...........................................................................1412 E-7 Brake lamp does not light or it keeps lighting up....................................................................................1418 E-8 Backup lamp does not light or it keeps lighting up...................................................................................1420 E-9 Backup buzzer does not sound or it keeps sounding....................................................................................1422 E-10 Horn does not sound or it keeps sounding............................................................................................1424 E-11 Alarm buzzer does not sound or it keeps sounding....................................................................................1427 E-12 Air conditioner does not operate or stop............................................................................................1429 E-13 KOMTRAX system does not work properly...............................................................................................1432 E-14 Electric priming pump does not operate or does not stop automatically...............................................................1434 Troubleshooting of hydraulic and mechanical system (H-mode)..................................................................................1437 Method of using troubleshooting chart....................................................................................................1439 Table of failure modes and causes........................................................................................................1442 H-1 Machine does not start...............................................................................................................1446 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...............................1448 H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)]................................................1449 H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted...............................1450 H-5 Shocks are large at the times of starting and shifting gear..........................................................................1452 H-6 Time lag is large at the times of starting and shifting gear.........................................................................1454 H-7 Torque converter oil temperature is high.............................................................................................1456 H-8 Steering does not turn...............................................................................................................1457 H-9 Steering does not turn [Machine with joystick steering (if equipped)]................................................................1458 H-10 Steering response is low............................................................................................................1459 H-11 Turning response of steering is poor [machine with joystick steering (if equipped)].................................................1460 H-12 Steering is heavy...................................................................................................................1461 H-13 When machine turns, it shakes or makes large shocks.................................................................................1462 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]..................................1463 H-15 Wheel brake does not work or does not work well.....................................................................................1464 H-16 Wheel brake is not released or it drags.............................................................................................1465 H-17 Parking brake does not work or does not work well...................................................................................1466 H-18 Parking brake is not released or it drags (including emergency release system)......................................................1467 H-19 Lift arm does not rise..............................................................................................................1468 H-20 Lift arm speed is low or rising force of lift arm is insufficient...................................................................1469 H-21 When rising, lift arm comes to move slowly at specific height.......................................................................1470 H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)...........................................................................1470 H-23 Hydraulic drifts of lift arm occur often............................................................................................1470 H-24 Lift arm wobbles during operation...................................................................................................1470 H-25 Bucket does not tilt back...........................................................................................................1471 H-26 Bucket speed is low or tilting back force is insufficient...........................................................................1472 H-27 Bucket comes to operate slowly in the midst of tilting-back.........................................................................1473 H-28 Bucket cylinder cannot hold down the bucket.........................................................................................1473 H-29 Hydraulic drifts of bucket occur often..............................................................................................1473 H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”).....................................................1473 H-31 During operation of machine, engine speed lowers remarkably or engine stalls........................................................1474 H-32 Large shocks are made when work equipment starts and stops..........................................................................1474 H-33 When work equipment circuit is relieved singly, other work equipment moves..........................................................1474 H-34 ECSS does not operate, and pitching and bouncing occur..............................................................................1475 Troubleshooting of engine (S-mode)...........................................................................................................1477 Method of using troubleshooting chart....................................................................................................1479 S-1 Engine does not start easily.........................................................................................................1482 S-2 Engine does not start................................................................................................................1483 S-3 Engine does not pick up smoothly.....................................................................................................1486 S-4 Engine stops during operation........................................................................................................1487 S-5 Engine does not rotate smoothly (Engine hunts.)......................................................................................1488 S-6 Engine lacks output (or lacks power).................................................................................................1489 S-7 Exhaust smoke is black (Incomplete combustion).......................................................................................1490 S-8 Oil is consumed much (or exhaust gas color is blue)..................................................................................1491 S-9 Engine oil becomes contaminated quickly..............................................................................................1492 S-10 Fuel consumption is excessive.......................................................................................................1493 S-11 Coolant contains oil (blows back or reduces)........................................................................................1494 S-12 Oil pressure drops..................................................................................................................1495 S-13 Oil level rises (Water, fuel in oil)................................................................................................1496 S-14 Coolant temperature rises too high (Overheating)....................................................................................1497 S-15 Abnormal noise is made..............................................................................................................1498 S-16 Vibration is excessive..............................................................................................................1499 S-17 Air cannot be bled from fuel circuit................................................................................................1500 50 Disassembly and assembly......................................................................................................................1503 General information on disassembly and assembly..............................................................................................1503 How to read this manual..................................................................................................................1504 Coating materials list...................................................................................................................1506 Special tool list........................................................................................................................1509 Sketches of special tools................................................................................................................1513 Engine and cooling system (SAA6D140E-5)......................................................................................................1521 Removal and installation of engine assembly..............................................................................................1522 Removal and installation of radiator assembly............................................................................................1527 Removal and installation of air aftercooler..............................................................................................1529 Removal and installation of cooling fan and fan motor assembly...........................................................................1530 Removal and installation of radiator guard and cooling fan motor assembly................................................................1532 Removal and installation of fuel tank assembly...........................................................................................1535 Removal and installation of hood.........................................................................................................1537 Engine (SAA6D140E-5).........................................................................................................................1541 Removal and installation of fuel supply pump assembly....................................................................................1542 Removal and installation of cylinder head assembly.......................................................................................1546 Removal and installation of fuel injector assembly.......................................................................................1557 Removal and installation of engine front seal............................................................................................1560 Removal and installation of engine rear seal.............................................................................................1564 Power train, Part 1..........................................................................................................................1571 Removal and installation of torque converter and transmission assembly...................................................................1572 Disconnection and connection of power train unit.........................................................................................1578 Disassembly and assembly of input transfer assembly......................................................................................1582 Disassembly and assembly of torque converter assembly (Lockup specification).............................................................1589 Disassembly and assembly of torque converter assembly (Lockup-less specification)........................................................1602 Power train, Part 2..........................................................................................................................1615 Disassembly and assembly of transmission assembly........................................................................................1616 Disassembly and assembly of transfer and parking brake assembly..........................................................................1646 Removal and installation of front axle assembly..........................................................................................1663 Removal and installation of rear axle assembly...........................................................................................1665 Power train, Part 3..........................................................................................................................1669 Removal and installation of front differential assembly..................................................................................1670 Disassembly and assembly of differential assembly (LSD specification)....................................................................1672 Disassembly and assembly of differential assembly (LSD-less specification)...............................................................1686 Disassembly and assembly of final drive assembly (Front and rear)........................................................................1697 Brake system.................................................................................................................................1705 Removal and installation of brake assembly (Front and rear)..............................................................................1706 Disassembly and assembly of brake assembly (Front and rear)..............................................................................1710 Disassembly and assembly of slack adjuster assembly......................................................................................1716 Disassembly and assembly of brake accumulator charge valve assembly......................................................................1717 Undercarriage and frame......................................................................................................................1719 Removal and installation of center hinge pin.............................................................................................1720 Removal and installation of large counterweight assembly.................................................................................1727 Removal and installation of small counterweight assembly.................................................................................1728 Hydraulic system.............................................................................................................................1731 Removal and installation of hydraulic tank assembly......................................................................................1732 Removal and installation of cooling pump assembly........................................................................................1735 Removal and installation of fan pump assembly............................................................................................1736 Removal and installation of work equipment pump assembly.................................................................................1737 Removal and installation of steering, torque converter charge and EPC pump assembly......................................................1739 Removal and installation of work equipment valve assembly................................................................................1740 Disassembly and assembly of work equipment control valve assembly........................................................................1743 Disassembly and assembly of steering cylinder assembly...................................................................................1746 Disassembly and assembly of lift arm and bucket cylinder assembly........................................................................1750 Removal and installation of steering valve assembly......................................................................................1756 Work equipment...............................................................................................................................1759 Removal and installation of work equipment assembly......................................................................................1760 Cab and its attachments......................................................................................................................1765 Removal and installation of operator's cab assembly (Separate cab and floor specification)...............................................1766 Removal and installation of operator's cab and floor frame assembly (Cab-floor unit specification).......................................1771 Removal and installation of operator's cab glass (Stuck glass)...........................................................................1775 Disassembly and assembly of operator's seat assembly.....................................................................................1784 Electrical system............................................................................................................................1819 Removal and installation of engine controller assembly...................................................................................1820 Removal and installation of transmission controller assembly.............................................................................1821 Removal and installation of work equipment controller assembly...........................................................................1822 Removal and installation of air conditioner unit assembly................................................................................1823 80 Appendix......................................................................................................................................1829 Air conditioner..............................................................................................................................1829 Precautions for refrigerant..............................................................................................................1831 Troubleshooting procedure................................................................................................................1832 Circuit diagram and arrangement of connector pins........................................................................................1834 System diagram...........................................................................................................................1839 Detail of air conditioner unit...........................................................................................................1841 Parts and connectors layout..............................................................................................................1843 Testing with self-diagnosis function (indication on control panel).......................................................................1847 Testing temperature control..............................................................................................................1850 Testing vent (mode) changeover...........................................................................................................1851 Testing Fresh/Recirc changeover..........................................................................................................1853 Testing inside air temp. sensor and outside air temp. sensor.............................................................................1855 Testing evaporator temperature sensor....................................................................................................1857 Testing sunlight sensor..................................................................................................................1858 Testing relays...........................................................................................................................1859 Troubleshooting chart 1..................................................................................................................1860 Troubleshooting chart 2..................................................................................................................1861 Information in troubleshooting table.....................................................................................................1864 Troubleshooting for power supply system (Air conditioner does not operate)...............................................................1865 Troubleshooting for compressor and refrigerant system (Air is not cooled)................................................................1868 Troubleshooting for blower motor system (No air comes out or air flow is abnormal).......................................................1871 Troubleshooting for temperature control..................................................................................................1877 Troubleshooting for vent (mode) changeover...............................................................................................1880 Troubleshooting for Fresh/Recirc air changeover..........................................................................................1883 Troubleshooting with gauge pressure......................................................................................................1885 Connection of service tool...............................................................................................................1887 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit..................................................1888 Handling of compressor oil...............................................................................................................1890 90 Diagrams and drawings.........................................................................................................................1893 Hydraulic diagrams and drawings..............................................................................................................1893 Power train hydraulic circuit diagram....................................................................................................1895 Brake hydraulic circuit diagram..........................................................................................................1899 Work equipment hydraulic circuit diagram.................................................................................................1903 Electrical diagrams and drawings.............................................................................................................1907 Engine electrical circuit diagram........................................................................................................1908 Air conditioner electrical circuit diagram...............................................................................................1909 Electrical circuit diagram...............................................................................................................1911 Connector arrangement diagram............................................................................................................1925
DESCRIPTION:
KOMATSU WA500-6R WHEEL LOADER SHOP MANUAL SEN02876-16 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
S.S 30/12/24
