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Komatsu ecot3 WA500-6 Shop Manual

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SEN00236-19
WHEEL LOADER
WA500
-6
55001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu ecot3 WA500-6

  • Page 1 SEN00236-19 WHEEL LOADER WA500 55001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SEN00701-19 WHEEL LOADER 1SHOP MANUAL WA500-6 Machine model Serial number WA500-6 55001 and up 00 Index and foreword Index Composition of shop manual .......................... 2 Table of contents ............................. 4 WA500-6 Find manuals at https://best-manuals.com...

  • Page 4: Composition Of Shop Manual

    SEN00701-19 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
  • Page 5 00 Index and foreword SEN00701-19 Troubleshooting by failure code (Display of code), Part 2 SEN00731-03 Troubleshooting by failure code (Display of code), Part 3 SEN00732-04 Troubleshooting by failure code (Display of code), Part 4 SEN00733-04 Troubleshooting by failure code (Display of code), Part 5 SEN00734-03 Troubleshooting by failure code (Display of code), Part 6 SEN00735-01...
  • Page 6 SEN00701-19 00 Index and foreword Table of contents 00 Index and foreword Index SEN00701-19 Composition of shop manual ....................Table of contents........................Foreword and general information SEN00702-05 Safety notice ..........................How to read the shop manual....................Explanation of terms for maintenance standard ..............Handling of electric equipment and hydraulic component ............
  • Page 7 00 Index and foreword SEN00701-19 Steering valve .......................... 15 Stop valve ..........................19 Joystick steering lever linkage (if equipped)................20 Steering cylinder ........................21 Emergency steering piping diagram (if equipped) ..............24 Diverter valve........................... 25 Brake system SEN00707-02 Brake piping diagram....................... Brake valve..........................
  • Page 8 SEN00701-19 00 Index and foreword Horn circuit..........................20 Wiper and window washer circuits................... 21 Sensor ............................. 24 KOMTRAX system........................42 20 Standard value table Standard service value table SEN00724-05 Standard service value table for engine................... Standard service value table for chassis ................. 30 Testing and adjusting Testing and adjusting, Part 1 SEN00725-07...
  • Page 9 00 Index and foreword SEN00701-19 Measuring and adjusting work equipment control lever ............37 Testing and adjusting work equipment PPC oil pressure ............38 Measuring work equipment oil pressure.................. 40 Bleeding air from work equipment circuit................. 46 Releasing residual pressure in work equipment circuit ............47 Method of moving machine when removing operator cab (when separate cab and floor specification) ......................
  • Page 10 SEN00701-19 00 Index and foreword Failure code [AB00MA] Alternator: Malfunction................. 13 Failure code [B@BAZG] Low engine oil pressure ..............15 Failure code [B@BAZK] Engine oil: Low level................16 Failure code [B@BCNS] Coolant: Overheating................. 18 Failure code [B@BCZK] Coolant: Low level................20 Failure code [b@CENS] Torque converter oil: Overheating ............
  • Page 11 00 Index and foreword SEN00701-19 Failure code [CA1228] EGR valve servo error 1 ..............58 Failure code [CA1625] EGR valve servo error 2 ..............59 Failure code [CA1626] Bypass valve solenoid current high error..........60 Failure code [CA1627] Bypass valve solenoid current low error ..........62 Failure code [CA1628] Bypass Valve Servo Error 1 ..............
  • Page 12 SEN00701-19 00 Index and foreword Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range ............................24 Failure code [DB99KQ] Work equipment controller model selection: Disagreement of model selec- tion signals........................26 Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormality in target component system) ...............
  • Page 13 00 Index and foreword SEN00701-19 Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) ....10 Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine) ........12 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)....14 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) .................
  • Page 14 SEN00701-19 00 Index and foreword Troubleshooting by failure code (Display of code), Part 9 SEN00738-01 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) ........Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)........Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) .. Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) ..........
  • Page 15 00 Index and foreword SEN00701-19 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ......39 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) ......40 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line) ......................41 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) ......
  • Page 16 SEN00701-19 00 Index and foreword H-25 Bucket does not tilt back ....................35 H-26 Bucket speed is low or tilting back force is insufficient ........... 36 H-27 Bucket comes to operate slowly in the midst of tilting-back..........37 H-28 Bucket cylinder cannot hold down the bucket..............37 H-29 Hydraulic drifts of bucket occur often ................
  • Page 17 00 Index and foreword SEN00701-19 Power train, Part 2 SEN02026-04 Disassembly and assembly of transmission assembly............Disassembly and assembly of transfer and parking brake assembly ........32 Removal and installation of front axle assembly ..............48 Removal and installation of rear axle assembly ..............50 Power train, Part 3 SEN02027-04 Removal and installation of front differential assembly............
  • Page 18 SEN00701-19 WA500-6 Wheel loader Form No. SEN00701-19 © 2017 KOMATSU All Rights Reserved Printed in Japan 07-17 (01)

  • Page 19: Index And Foreword

    SEN00702-05 WHEEL LOADER 1SHOP MANUAL WA500-6 Machine model Serial number WA500-6 55001 and up 00 Index and foreword Foreword and general information Safety notice ..............................2 How to read the shop manual ......................... 7 Explanation of terms for maintenance standard ..................... 9 Handling of electric equipment and hydraulic component ................11 Handling of connectors newly used for engines ...................

  • Page 20: Safety Notice

    Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
  • Page 21 Safety notice SEN00702-05 Preparations for work Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground.
  • Page 22 SEN00702-05 Safety notice 12) When assembling or installing parts, Limit the hanging angle to 60°, as a rule. always tighten them to the specified Do not sling a heavy load with ropes form- torques. When installing protective parts ing a wide hanging angle from the hook. such as guards, or parts which vibrate vio- When hoisting a load with 2 or more lently or rotate at high speed, be particu-...
  • Page 23 Safety notice SEN00702-05 Precautions for using overhead hoist crane When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disas- sembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock preven-...
  • Page 24 SEN00702-05 Safety notice Selecting wire ropes Connection Select adequate ropes depending on the When installing the air conditioner cir- weight of parts to be hoisted, referring to cuit hoses and tubes, take care that the table below. dirt, dust, water, etc. will not enter them.

  • Page 25: How To Read The Shop Manual

    Engine volume This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. WA500-6...
  • Page 26 SEN00702-05 How to read the shop manual Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.

  • Page 27: Explanation Of Terms For Maintenance Standard

    Explanation of terms for maintenance standard SEN00702-05 Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
  • Page 28 SEN00702-05 Explanation of terms for maintenance standard Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.

  • Page 29: Handling Of Electric Equipment And Hydraulic Component

    Handling of electric equipment and hydraulic component SEN00702-05 Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
  • Page 30 SEN00702-05 Handling of electric equipment and hydraulic component Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken.
  • Page 31 Handling of electric equipment and hydraulic component SEN00702-05 Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
  • Page 32 SEN00702-05 Handling of electric equipment and hydraulic component Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins.
  • Page 33 Handling of electric equipment and hydraulic component SEN00702-05 Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) Push in female connector (2) horizon- tally until the lock clicks.
  • Page 34 SEN00702-05 Handling of electric equipment and hydraulic component Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
  • Page 35 Handling of electric equipment and hydraulic component SEN00702-05 Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
  • Page 36 SEN00702-05 Handling of electric equipment and hydraulic component Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
  • Page 37 Handling of electric equipment and hydraulic component SEN00702-05 Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.

  • Page 38: Handling Of Connectors Newly Used For Engines

    SEN00702-05 Handling of connectors newly used for engines Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example) 114E-3 Intake air temperature sensor in 125E-5...
  • Page 39 Handling of connectors newly used for engines SEN00702-05 Push lock type 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engines Example)
  • Page 40 SEN00702-05 Handling of connectors newly used for engines 95, 125 – 170, 12V140 engines Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pull out connector (5) in the direction of Example) the arrow. Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc.

  • Page 41: How To Read Electric Wire Code

    How to read electric wire code SEN00702-05 How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols.
  • Page 42 SEN00702-05 How to read electric wire code Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29...
  • Page 43 How to read electric wire code SEN00702-05 Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue &...

  • Page 44: Precautions When Carrying Out Operation

    SEN00702-05 Precautions when carrying out operation Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.
  • Page 45 Precautions when carrying out operation SEN00702-05 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
  • Page 46 SEN00702-05 Precautions when carrying out operation Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.

  • Page 47: Method Of Disassembling And Connecting Push-Pull Type Coupler

    Method of disassembling and connecting push-pull type coupler SEN00702-05 Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
  • Page 48 SEN00702-05 Method of disassembling and connecting push-pull type coupler Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
  • Page 49 Method of disassembling and connecting push-pull type coupler SEN00702-05 Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por-...

  • Page 50: Standard Tightening Torque Table

    SEN00702-05 Standard tightening torque table Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque...
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