Komatsu WA500-7 Wheel Loader Shop Manual SEN05693–PDI PDF

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Komatsu WA500-7 Wheel Loader Shop Manual SEN05693–PDI – PDF DOWNLOAD

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Komatsu WA500-7 Wheel Loader Shop Manual SEN05693–PDI – PDF DOWNLOAD 

Language : English
Pages : 677
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693–PDI – PDF DOWNLOAD 

Serial Numbers 10001 and up

20 Standard value tables 3
Table of contents 4
Standard service value table 5
Standard value table for engine 5
Standard value table for machine 7
30 Testing and adjusting 19
Table of contents 20
Engine and cooling system 21
Measuring engine speed 21
Replacing and adjusting belt for alternator and air conditioner compressor 23
Power train 24
Testing and adjusting power train oil pressure 24
Brake system 38
Testing wheel brake oil pressure 38
Work equipment 39
Testing and adjusting bucket position detection lever 39
Testing and adjusting boom position detection lever 40
Electrical system 41
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 41
Special functions of machine monitor 43
Pm clinic 131
Pm Clinic service 131
Check sheet 132
40 Troubleshooting 139
Table of contents 140
Troubleshooting by failure code (Display of code) 146
Failure codes table 146
Failure code [1500L0] Double Engagement of T/M Clutches 160
Failure code [15B0NX] Transmission Oil Filter Clogging 161
Failure code [15SAL1] Release Trouble of ECMV (Forward) 162
Failure code [15SALH] Malfunction of ECMV (Forward) 164
Failure code [15SBL1] Release Trouble of ECMV (Reverse) 166
Failure code [15SBLH] Malfunction of ECMV (Reverse) 168
Failure code [15SEL1] Release Trouble of ECMV (1st clutch) 170
Failure code [15SELH] Malfunction of ECMV (1st) 172
Failure code [15SFL1] Release Trouble of ECMV (2nd) 174
Failure code [15SFLH] Malfunction of ECMV (2nd) 176
Failure code [15SGL1] Release Trouble of ECMV (3rd) 178
Failure code [15SGLH] Malfunction of ECMV (3rd) 180
Failure code [15SHL1] Release Trouble of ECMV (4th) 182
Failure code [15SHLH] Malfunction of ECMV (4th) 184
Failure code [2F00MA] Failure of Parking Brake Circuit 186
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 189
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 191
Failure code [879AKA] A/C Inner Sensor Open Circuit 193
Failure code [879AKB] A/C Inner Sensor Short Circuit 194
Failure code [879BKA] A/C Outer Sensor Open Circuit 195
Failure code [879BKB] A/C Outer Sensor Short Circuit 196
Failure code [879CKA] Ventilating Sensor Open Circuit 197
Failure code [879CKB] Ventilating Sensor Short Circuit 198
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 199
Failure code [879EMC] Ventilation Damper Abnormality 200
Failure code [879FMC] Air Mix Damper Abnormality 201
Failure code [989A00] Engine Overrun Prevention Activated 202
Failure code [989L00] Engine Controller Lock Caution 1 203
Failure code [989M00] Engine Controller Lock Caution 2 204
Failure code [989N00] Engine Controller Lock Caution 3 205
Failure code [A1U0N3] HC Desorb Request 1 206
Failure code [A1U0N4] HC Desorb Request 2 208
Failure code [AA10NX] Air Cleaner Clogging 210
Failure code [B@BAZG] Eng Oil Press Low 212
Failure code [B@BCNS] Eng Water Overheat 213
Failure code [B@BCZK] Eng Water Level Low 214
Failure code [B@CENS] T/C Oil Temp Overheat 216
Failure code [B@HANS] HYD Oil Temp Overheat 217
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 218
Failure code [CA122] Chg Air Press Sensor High Error 219
Failure code [CA123] Chg Air Press Sensor Low Error 221
Failure code [CA131] Throttle Sensor High Error 223
Failure code [CA132] Throttle Sensor Low Error 225
Failure code [CA135] Eng Oil Press Sensor High Error 227
Failure code [CA141] Eng Oil Press Sensor Low Error 229
Failure code [CA144] Coolant Temp Sens High Error 231
Failure code [CA145] Coolant Temp Sens Low Error 233
Failure code [CA153] Chg Air Temp Sensor High Error 235
Failure code [CA154] Chg Air Temp Sensor Low Error 237
Failure code [CA187] Sensor 2 Supply Volt Low Error 239
Failure code [CA221] Ambient Press Sens High Error 241
Failure code [CA222] Ambient Press Sens Low Error 243
Failure code [CA227] Sensor 2 Supply Volt High Error 245
Failure code [CA234] Eng Overspeed 246
Failure code [CA238] Ne Speed Sensor Supply Volt Error 247
Failure code [CA239] Ne Speed Sens Supply Volt High Error 248
Failure code [CA271] IMV/PCV1 Short Error 249
Failure code [CA272] IMV/PCV1 Open Error 250
Failure code [CA273] PCV2 Short Error 251
Failure code [CA274] PCV2 Open Error 252
Failure code [CA322] Inj #1(L#1) Open/Short Error 253
Failure code [CA323] Inj #5(L#5) Open/Short Error 255
Failure code [CA324] Inj #3(L#3) Open/Short Error 257
Failure code [CA325] Inj #6(L#6) Open/Short Error 259
Failure code [CA331] Inj #2(L#2) Open/Short Error 261
Failure code [CA332] Inj #4(L#4) Open/Short Error 263
Failure code [CA343] ECM Critical Internal Failure 265
Failure code [CA351] Injectors Drive Circuit Error 266
Failure code [CA352] Sensor 1 Supply Volt Low Error 267
Failure code [CA356] Mass Air Flow Sensor High Error 269
Failure code [CA357] Mass Air Flow Sensor Low Error 271
Failure code [CA386] Sensor 1 Supply Volt High Error 273
Failure code [CA431] Idle Validation Sw Error 274
Failure code [CA432] Idle Validation Process Error 277
Failure code [CA441] Battery Voltage Low Error 280
Failure code [CA442] Battery Voltage High Error 282
Failure code [CA449] Rail Press Very High Error 283
Failure code [CA451] Rail Press Sensor High Error 284
Failure code [CA452] Rail Press Sensor Low Error 286
Failure code [CA515] Rail Press Sens Sup Volt High Error 288
Failure code [CA516] Rail Press Sens Sup Volt Low Error 290
Failure code [CA553] Rail Press High Error 292
Failure code [CA555] Crankcase Press High Error 2 293
Failure code [CA556] Crankcase Press High Error 3 294
Failure code [CA559] Rail Press Low Error 295
Failure code [CA595] Turbo Speed High Error 2 299
Failure code [CA687] Turbo Speed Low Error 300
Failure code [CA689] Eng Ne Speed Sensor Error 302
Failure code [CA691] Intake Air Temp Sens High Error 304
Failure code [CA692] Intake Air Temp Sens Low Error 306
Failure code [CA697] ECM Internal Temp Sensor High Error 308
Failure code [CA698] ECM Int Temp Sensor Low Error 309
Failure code [CA731] Eng Bkup Speed Sens Phase Error 310
Failure code [CA778] Eng Bkup Speed Sensor Error 311
Failure code [CA1117] Persistent Data Lost Error 313
Failure code [CA1664] KDOC Malfunction 314
Failure code [CA1691] Regeneration Ineffective 317
Failure code [CA1695] Sensor 5 Supply Volt High Error 320
Failure code [CA1696] Sensor 5 Supply Volt Low Error 321
Failure code [CA1843] Crankcase Press Sens High Error 323
Failure code [CA1844] Crankcase Press Sens Low Error 325
Failure code [CA1879] KDPF Delta P Sensor High Error 327
Failure code [CA1881] KDPF Delta P Sensor Low Error 329
Failure code [CA1883] KDPF Delta P Sens In Range Error 331
Failure code [CA1921] KDPF Soot Load High Error 1 334
Failure code [CA1922] KDPF Soot Load High Error 2 336
Failure code [CA1923] Dosing Fuel Valve 1 High Error 340
Failure code [CA1924] Dosing Fuel Valve 1 Low Error 342
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error 345
Failure code [CA1927] Dosing Fuel Press Sens High Error 347
Failure code [CA1928] Dosing Fuel Press Sens Low Error 349
Failure code [CA1942] Crankcase Press Sens In Range Error 351
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error 352
Failure code [CA1977] Fuel Doser Open/Short Error 354
Failure code [CA1993] KDPF Delta Pressure Low Error 356
Failure code [CA2185] Throt Sensor Sup Volt High Error 359
Failure code [CA2186] Throt Sensor Sup Volt Low Error 361
Failure code [CA2249] Rail Press Very Low Error 363
Failure code [CA2265] Fuel Feed Pump Open Error 364
Failure code [CA2266] Fuel Feed Pump Short Error 366
Failure code [CA2271] EGR Valve Pos Sens High Error 368
Failure code [CA2272] EGR Valve Pos Sens Low Error 370
Failure code [CA2349] EGR Valve Solenoid Open Error 372
Failure code [CA2353] EGR Valve Solenoid Short Error 374
Failure code [CA2357] EGR Valve Servo Error 376
Failure code [CA2381] KVGT Pos Sens High Error 377
Failure code [CA2382] KVGT Pos Sens Low Error 379
Failure code [CA2383] KVGT Solenoid Open Error 381
Failure code [CA2386] KVGT Solenoid Short Error 383
Failure code [CA2387] KVGT Servo Error 385
Failure code [CA2555] Grid Htr Relay Volt Low Error 386
Failure code [CA2556] Grid Htr Relay Volt High Error 388
Failure code [CA2637] KDOC Face Plugging 390
Failure code [CA2639] Manual Stationary Regeneration Request 392
Failure code [CA2732] Dosing Fuel Valve 2 High Error 394
Failure code [CA2733] Dosing Fuel Valve 2 Low Error 396
Failure code [CA2741] Dosing Fuel Valve Swap Error 398
Failure code [CA2765] Inj Trim Data Error 399
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error 400
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 403
Failure code [CA3133] KDPF Outlet Press Sens High Error 406
Failure code [CA3134] KDPF Outlet Press Sens Low Error 408
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 410
Failure code [CA3167] Fuel Doser Degradation 413
Failure code [CA3251] KDOC Inlet Temp High Error 416
Failure code [CA3253] KDOC Temp Error – Non Regeneration 419
Failure code [CA3254] KDOC Outlet Temp High Error 1 422
Failure code [CA3255] KDPF Temp Error – Non Regeneration 425
Failure code [CA3256] KDPF Outlet Temp High Error 1 429
Failure code [CA3311] KDOC Outlet Temp High Error 2 432
Failure code [CA3312] KDPF Outlet Temp High Error 2 435
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 438
Failure code [CA3314] KDOC Inlet Temp Sens High Error 441
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 444
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 448
Failure code [CA3317] KDOC Outlet Temp Sens High Error 451
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 454
Failure code [CA3319] KDPF Outlet Temp Sens High Error 457
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 460
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 462
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 465
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 467
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 469
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output 471
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 473
Failure code [D191KA] Disconnection of Neutral Output Relay 475
Failure code [D191KB] Ground Fault of Neutral Output Relay 477
Failure code [D191KY] Hot Short of Neutral Output Relay 479
Failure code [D192KA] Disconnection of ECSS Solenoid 481
Failure code [D192KB] Ground Fault of ECSS Solenoid 483
Failure code [D192KY] Hot Short of ECSS Solenoid 484
Failure code [D19JKZ] Personal Code Relay Abnormality 485
Failure code [D1E6KA] Disconnection of Parking Brake Relay 487
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 489
Failure code [D1E6KY] Hot Short of Parking Brake Relay 491
Failure code [D5ZHKA] Failure of Key SW C Signal 493
Failure code [D5ZHKB] Key SW C Signal Short Circuit 495
Failure code [D5ZHKZ] Failure of Key SW C Signal 497
Failure code [D5ZHL6] Disconnection of Key SW C 499
Failure code [D5ZMLD] Ground Fault of Eng Power Selection SW 501
Failure code [D811MC] KOMTRAX Error 503
Failure code [D862KA] GPS Antenna Open Circuit 504
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 505
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 507
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 509
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 510
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 512
Failure code [DAF0MB] Monitor ROM Abnormality 513
Failure code [DAF0MC] Monitor Error 514
Failure code [DAF3KK] Controller Power Source Low (MON) 515
Failure code [DAF8KB] Camera Power Supply Short Circuit 517
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 518
Failure code [DAFGMC] GPS Module Error 520
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 521
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 523
Failure code [DAFQKR] CAN2 Discon (Monitor) 525
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 526
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) 527
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 529
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 531
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 532
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) 533
Failure code [DAZ9KQ] A/C Model Selection Abnormality 534
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 535
Failure code [DB2QKR] CAN2 Discon (Engine Con) 536
Failure code [DB2RKR] CAN1 Discon (Engine Con) 541
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) 546
Failure code [DB90MC] BBC Error 547
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) 548
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) 549
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) 551
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) 553
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) 554
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) 555
Failure code [DDAAL6] Disconnection of Secondary ENG Stop SW 556
Failure code [DGR2KB] Ground Fault of Brake Oil Temp Sensor 558
Failure code [DGR2KZ] Failure of Brake Oil Temp Sensor 559
Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit 561
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 563
Failure code [DPQ1KR] LIN Discon (Switch Panel) 564
Failure code [DPQ2KR] LIN Discon (LED Unit) 567
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 570
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 573
Failure code [DV00KB] Ground Fault of Buzzer Output 575
Troubleshooting of hydraulic and mechanical system (H-mode) 576
Information described in troubleshooting table (H-mode) 576
System chart of hydraulic and mechanical systems 577
Failure mode and cause table 581
H-1 Machine does not start 590
H-2 Torque converter lockup clutch is not disengaged (engine stalls) 593
H-3 Torque converter lockup clutch is not engaged 594
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift 595
H-5 Large shock is made when machine starts or gear is shifted 598
H-6 Machine starts or gear speed shifts with long time lag 600
H-7 Torque converter oil temperature is high 602
H-8 Machine does not turn 604
H-9 Turning response is poor 606
H-10 Steering wheel is heavy to turn 608
H-11 Machine sways or large shocks are made while machine turns 609
H-12 Turning radius differs between right and left turns 611
H-13 Wheel brakes do not work or are weak 612
H-14 Wheel brakes are not released or drag 614
H-15 Parking brake does not work or it is weak 615
H-16 Parking brake is not released or drags (including emergency release system) 616
H-17 Boom does not rise 617
H-18 Boom moves slow or boom lacks lifting force 619
H-19 Rising boom slows down at certain height 621
H-20 Lift cylinders do not serve to hold bucket on ground 622
H-21 Hydraulic drift of boom is large 623
H-22 Boom moves up and down during operation 624
H-23 Bucket does not tilt back 625
H-24 Bucket moves slow or bucket lacks tilt-back force 627
H-25 Bucket decelerates during tilt-back operation 629
H-26 Bucket cylinder does not hold bucket on ground 630
H-27 Hydraulic drift of bucket is large 631
H-28 Bucket tilts back and forth during carrying load (work equipment valve in “HOLD”) 632
H-29 Boom and bucket control levers do not move smoothly and are heavy to move 633
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall 634
H-31 Large shocks are made when work equipment starts to move and stops 635
H-32 When certain work equipment stalls hydraulically, other work equipment moves 637
H-33 E C S S (travel damper) does not work and machine pitches and bounces 638
H-34 Fan speed is abnormal (too high or low, or fan does not rotate) 639
H-35 Unusual noise is heard from around fan 640
Troubleshooting of engine (S-mode) 641
Information mentioned in troubleshooting table (S mode) 641
S-1 When starting switch is turned to START position, engine is not cranked 642
S-2 The engine cranks but exhaust smoke does not come out 643
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 644
S-4 Startability is poor 645
S-5 Engine does not pick-up smoothly 648
S-6 Engine stops during operation 651
S-7 Engine runs rough or is unstable 653
S-8 Engine lacks power 654
S-9 Exhaust gas is black (KDPF gets clogged in a short time) 656
S-10 Engine oil consumption is excessive 658
S-11 Engine oil becomes contaminated early 659
S-12 Fuel consumption is excessive 660
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 661
S-14 Oil pressure drops 662
S-15 Fuel mixes into engine oil 663
S-16 Water mixes into engine oil (milky) 664
S-17 Coolant temperature rises too high (overheating) 665
S-18 Unusual noise is made 666
S-19 Vibration is excessive 667
S-20 Air cannot be bled from fuel circuit 668
S-21 Active regeneration is executed frequently 669
S-22 Active regeneration takes a long time 670
S-23 White smoke is exhausted during active regeneration 671

S.V 16/12/24