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Komatsu WA500-6 Shop Manual

Wheel loader
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WA500-6
WHEEL LOADER
SERIAL NUMBERS
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
December 2013
Printed in USA
WA500-6
A93001
Copyright 2013 Komatsu
DataKom Publishing Division
CEBM022903
and UP
00-1
d

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Summary of Contents for Komatsu WA500-6

  • Page 1 SERIAL NUMBERS and UP This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 DIAGRAMS AND SCHEMATICS..........90-1 00-2 WA500-6 Find manuals at https://best-manuals.com...
  • Page 3 00-32 10-5 10-34 00-3 00-33 10-6 10-35 00-4 ● 00-34 10-7 10-36 00-5 00-35 10-8 10-37 00-6 00-36 10-9 10-38 00-7 00-37 10-10 10-39 00-8 00-38 10-11 10-40 00-9 00-39 10-12 10-41 00-10 WA500-6 00-2-1 WA500-6 Find manuals at https://best-manuals.com...
  • Page 4 10-132 10-165 10-67 10-100 10-133 10-166 10-68 10-101 10-134 10-167 10-69 10-102 10-135 10-168 10-70 10-103 10-136 10-169 10-71 10-104 10-137 10-170 10-72 10-105 10-138 10-171 10-73 10-106 10-139 10-172 10-74 10-107 10-140 10-173 00-2-2 WA500-6 Find manuals at https://best-manuals.com...
  • Page 5 10-264 10-297 10-232 10-265 10-298 10-199 10-200 10-233 10-266 10-299 10-201 10-234 10-267 10-300 10-202 10-235 10-268 10-301 10-203 10-236 10-269 10-302 10-204 10-237 10-270 10-303 10-205 10-238 10-271 10-304 10-206 10-239 10-272 10-305 WA500-6 00-2-3 Find manuals at https://best-manuals.com...
  • Page 6 10-396 10-429 10-331 10-364 10-397 10-430 10-332 10-365 10-398 10-431 10-333 10-366 10-399 10-432 10-334 10-367 10-400 10-433 10-335 10-368 10-401 10-434 10-336 10-369 10-402 10-435 10-337 10-370 10-403 10-436 10-338 10-371 10-404 10-437 00-2-4 WA500-6 Find manuals at https://best-manuals.com...
  • Page 7 30-8 30-41 10-496 30-9 30-42 10-463 10-464 10-497 30-10 30-43 10-465 10-498 30-11 30-44 10-466 10-499 30-12 30-45 10-467 10-500 30-13 30-46 10-468 10-501 30-14 30-47 10-469 10-502 30-15 30-48 10-470 10-503 30-16 30-49 WA500-6 00-2-5 Find manuals at https://best-manuals.com...
  • Page 8 30-140 30-173 30-75 30-108 30-141 30-174 30-76 30-109 30-142 30-175 30-77 30-110 30-143 30-176 30-78 30-111 30-144 30-177 30-79 30-112 30-145 30-178 30-80 30-113 30-146 30-179 30-81 30-114 30-147 30-180 30-82 30-115 30-148 30-181 00-2-6 WA500-6 Find manuals at https://best-manuals.com...
  • Page 9 40-49 40-82 40-17 40-50 40-83 30-207 30-208 40-18 40-51 40-84 30-209 40-19 40-52 40-85 30-210 40-20 40-53 40-86 30-211 40-21 40-54 40-87 30-212 40-22 40-55 40-88 30-213 40-23 40-56 40-89 30-214 40-24 40-57 40-90 WA500-6 00-2-7 Find manuals at https://best-manuals.com...
  • Page 10 40-181 40-214 40-116 40-149 40-182 40-215 40-117 40-150 40-183 40-216 40-118 40-151 40-184 40-217 40-119 40-152 40-185 40-218 40-120 40-153 40-186 40-219 40-121 40-154 40-187 40-220 40-122 40-155 40-188 40-221 40-123 40-156 40-189 40-222 00-2-8 WA500-6 Find manuals at https://best-manuals.com...
  • Page 11 40-312 40-345 40-247 40-280 40-313 40-346 40-248 40-281 40-314 40-347 40-249 40-282 40-315 40-348 40-250 40-283 40-316 40-349 40-251 40-284 40-317 40-350 40-252 40-285 40-318 40-351 40-253 40-286 40-319 40-352 40-254 40-287 40-320 40-353 40-255 40-288 40-321 40-354 WA500-6 00-2-9...
  • Page 12 40-444 40-477 40-379 40-412 40-445 40-478 40-380 40-413 40-446 40-479 40-381 40-414 40-447 40-480 40-382 40-415 40-448 40-481 40-383 40-416 40-449 40-482 40-384 40-417 40-450 40-483 40-385 40-418 40-451 40-484 40-386 40-419 40-452 40-485 40-387 40-420 40-453 40-486 00-2-10 WA500-6...
  • Page 13 40-576 40-609 40-511 40-544 40-577 40-610 40-512 40-545 40-578 40-611 40-513 40-546 40-579 40-612 40-514 40-547 40-580 40-613 40-515 40-548 40-581 40-614 40-516 40-549 40-582 40-615 40-517 40-550 40-583 40-616 40-518 40-551 40-584 40-617 40-519 40-552 40-585 40-618 WA500-6 00-2-11...
  • Page 14 40-708 40-741 40-643 40-676 40-709 40-742 40-644 40-677 40-710 40-743 40-645 40-678 40-711 40-744 40-646 40-679 40-712 40-745 40-647 40-680 40-713 40-746 40-648 40-681 40-714 40-747 40-649 40-682 40-715 40-748 40-650 40-683 40-716 40-749 40-651 40-684 40-717 40-750 00-2-12 WA500-6...
  • Page 15 50-37 50-70 40-775 50-5 50-38 50-71 40-776 50-6 50-39 50-72 40-777 50-7 50-40 50-73 40-778 50-8 50-41 50-74 40-779 50-9 50-42 50-75 40-780 50-10 50-43 50-76 40-781 50-11 50-44 50-77 40-782 50-12 50-45 50-78 40-783 50-13 50-46 50-79 WA500-6 00-2-13...
  • Page 16 50-169 50-202 50-104 50-137 50-170 50-203 50-105 50-138 50-171 50-204 50-106 50-139 50-172 50-205 50-107 50-140 50-173 50-206 50-108 50-141 50-174 50-207 50-109 50-142 50-175 50-208 50-110 50-143 50-176 50-209 50-111 50-144 50-177 50-210 50-112 50-145 50-178 50-211 00-2-14 WA500-6...
  • Page 17 50-301 50-334 50-236 50-269 50-302 50-335 50-237 50-270 50-303 50-336 50-238 50-271 50-304 50-337 50-239 50-272 50-305 50-338 50-240 50-273 50-306 50-339 50-241 50-274 50-307 50-340 50-242 50-275 50-308 50-341 50-243 50-276 50-309 50-342 50-244 50-277 50-310 50-343 WA500-6 00-2-15...
  • Page 18 60-9 60-42 ❍ ❍ 50-371 50-404 60-10 60-43 ❍ ❍ 50-372 50-405 60-11 60-44 ❍ ❍ 50-373 50-406 60-12 60-45 ❍ ❍ 50-374 50-407 60-13 60-46 ❍ ❍ 50-375 50-408 60-14 60-47 ❍ ❍ 50-376 50-409 60-15 60-48 00-2-16 WA500-6...
  • Page 19 90-26 ❍ 60-57 90-27 ❍ 60-58 90-28 ❍ 60-59 90-29 ❍ 60-60 90-30 ❍ 60-61 90-31 ❍ 60-62 90-32 90-33 90-1 90-2 90-3 90-4 90-5 90-6 90-7 90-8 90-9 90-10 90-11 90-12 90-13 90-14 90-15 90-16 90-17 90-18 WA500-6 00-2-17...
  • Page 20 FOREWORD Mark Page Mark Page Mark Page Mark Page 00-2-18 WA500-6...

  • Page 21: General Precautions

    Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these operations require the use of tools specially designed for the specific purpose.

  • Page 22: Preparations For Work

    Carefully review the safety and procedures for gradually and alternately to release the pressure and jump-starting the machine. then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 00-4 WA500-6...
  • Page 23 The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information. Some attachments and optional parts in this Shop Manual may not be available in certain areas. You can find complete technical information about the engine in a separate manual. 00-5 D WA500-6...
  • Page 24 Places where oil or water must be Additional pages: Additional pages are indicated by a Drain drained, and quantity to be hyphen (-) and numbered after the page number. File as drained. in the example. Example: 10-4 10-4-1 Added pages 10-4-2 10-5 00-6 WA500-6...

  • Page 25: Hoisting Instructions

    When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. WA500-6 00-7...
  • Page 26 12. Remember the position of the main switch so that you ★ Read the Operation & Maintenance Manual provided can turn off the power immediately in an emergency. with the crane in advance and operate the crane safely. 00-8 WA500-6...
  • Page 27 Do not leave the sling installed to the hook. 12.7 17.3 22.6 28.6 35.3 55.3 79.6 141.6 14.4 221.6 22.6 318.3 32.4 ★ The allowable load value is 1/6 of the breaking strength of the rope used. ★ Safety coefficient: 6 WA500-6 00-9...
  • Page 28 SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings. ★ See example of O-ring in the graphic. O-rings are fitted to every joint of the hoses and tubes. ★ For the tightening torque, see the precautions for installation in the appropriate Disassembly and Assembly sections. 00-10 WA500-6...
  • Page 29 (B) between the maximum size of the shaft and the minimum size of the hole is the standard interference. • After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. WA500-6 00-11...
  • Page 30 The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. • The interference limit shows the repair limit of the part of smaller tolerance. • If the interference between the parts exceeds the interference limit, they must be replaced or repaired. 00-12 WA500-6...
  • Page 31 The pins of the male and female connectors are in contact at the crimped terminal or soldered portion. If there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. WA500-6 00-13...
  • Page 32 • For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. ★ Never pull with one hand. 00-14 WA500-6...
  • Page 33 ★ If there is any damage or breakage, replace the connector. WA500-6 00-15...
  • Page 34 (2) while moving it up and down until the locks are set normally. (Arrows 1, 2, ★ Lock (a) is pulled down (not set completely) and lock (b) is set completely. • (1): Male connector • (2): Female connector • (a), (b): Locks 00-16 WA500-6...
  • Page 35 Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble. WA500-6 00-17...
  • Page 36 When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. ★ If there is any change, there is probably a defective contact in that circuit. 00-18 WA500-6...
  • Page 37 If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. WA500-6 00-19...
  • Page 38 The oil cleaning equipment is used to remove the ultra fine (about 3 µ) particles that the filter, built in the hydraulic equipment, cannot remove; it is an extremely effective device. 00-20 WA500-6...
  • Page 39 Even if lock (L2) is pressed, connector (1) cannot be pulled toward you if part A does not float. In this case, float part A with a small screwdriver while pressing lock (L2), and then pull out connector (1) toward you. WA500-6 00-21...
  • Page 40 While pressing lock (C), pull out connector (3) in the direction of the arrow. ★ 114 engine (see graphic) • If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. ★ 107 engine (see graphic) 00-22 WA500-6...
  • Page 41 While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Connector Sensor Fuel pressure sensor in common rail: AMP-3 PFUEL, etc. Connector Valve Injection pressure control valve of fuel SUMITOMO-2 supply pump: PCV WA500-6 00-23...
  • Page 42 ★ Housing (H1) is left on the wiring harness side. Connect the connector according to the following procedure. A. Insert the connector to the end, while setting its groove. B. Turn housing (H1) in the direction of the arrow until it clicks. 00-24 WA500-6...

  • Page 43: Precautions For Operations

    07376-70210 02789-20210 07376-70315 02789-20315 07376-70422 02789-20422 07376-70522 02789-20522 07376-70628 02789-20628 07376-71034 07221-21034 07376-71234 07221-21234 • Split flange type hoses and tubes Nominal Flange (hose end) Sleeve Head (tube end) Split Flange Number 07379-00400 07378-10400 07371-30400 07379-00500 07378-10500 07371-30500 WA500-6 00-25...
  • Page 44 Next, operate the hydraulic cylinder three to four times to the end of its stroke. After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, do the same procedure. 00-26 WA500-6...
  • Page 45 • Check the muffler for abnormal sound and sound different from that of a new muffler. • If any abnormal sound is heard, repair the muffler. ★ Refer to both the Troubleshooting and the Disassembly and Assembly sections. WA500-6 00-27...
  • Page 46 After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm (0.14 in). This does not indicate an abnormality. 00-28 WA500-6...
  • Page 47 (2) to disconnect it. Connection • Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect the body. WA500-6 00-29...
  • Page 48 Connection Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface (a) of the hexagonal portion at the male end to connect the body. 00-30 WA500-6...

  • Page 49: Coating Materials

    • Used as sealant for flange surfaces and Gasket bolts at high temperature locations; used to sealant LG-3 790-129-9070 1 kg prevent seizure. • Used as sealant for heat-resistant gasket for high-temperature locations such as engine precombustion chamber, exhaust pipe. WA500-6 00-31...
  • Page 50 • Used for normal temperature, light load G2-CA SYG2-400CA-A Various Various bearing at places in contact with water or Grease SYG2-160CA steam. SYG2-160CNCA 400 g SYG2-400M Belows type • Used for places with heavy load. (10 per case) 00-32 WA500-6...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...