Komatsu WA500-6 User manual

WHEEL LOADER

SEN00236-05

WA500

-6

SERIAL NUMBERS

55001

and up

WA500-6 1

SEN00701-05

WHEEL LOADER

1SHOP MANUAL

WA500-6

Machine model Serial number

WA500-6 55001 and up

00 Index and foreword 1

Index

Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 4

SEN00701-05 00 Index and foreword

2WA500-6

Composition of shop manual 1

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. denote the following:

Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)

Note 2: This shop manual can be supplied for each Form No.

Note 3: To file this shop manual in the special binder for management, handle it as follows:

• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated

next to each Section Name shown in the table below:

• File overview and other materials in sections in the order shown below and utilize them accord-

ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00236-05

00 Index and foreword SEN00575-05

Index SEN00701-05 q

Foreword and general information SEN00702-02 q

01 Specification SEN00576-01

Specification and technical data SEN00703-01 q

10 Structure, function and maintenance standard SEN00577-01

Engine and cooling system SEN00704-00

Power train, Part 1 SEN00705-01 q

Power train, Part 2 SEN00864-01 q

Steering system SEN00706-01 q

Brake system SEN00707-01 q

Undercarriage and frame SEN00708-01 q

Hydraulic system, Part 1 SEN00709-01 q

Hydraulic system, Part 2 SEN00875-01 q

Work equipment SEN00710-01 q

Cab and its attachments SEN00711-01 q

Electrical system, Part 1 SEN00712-01 q

Electrical system, Part 2 SEN00713-01 q

Electrical system, Part 3 SEN00874-01 q

20 Standard value table SEN00578-02

Standard service value table SEN00724-02

30 Testing and adjusting SEN00579-02

Testing and adjusting, Part 1 SEN00725-02

Testing and adjusting, Part 2 SEN00726-02

Testing and adjusting, Part 3 SEN00727-01

Testing and adjusting, Part 4 SEN00728-01

40 Troubleshooting SEN00580-01

General information on troubleshooting SEN00729-00

Troubleshooting by failure code (Display of code), Part 1 SEN00730-01

00 Index and foreword SEN00701-05

WA500-6 3

Troubleshooting by failure code (Display of code), Part 2 SEN00731-01

Troubleshooting by failure code (Display of code), Part 3 SEN00732-01

Troubleshooting by failure code (Display of code), Part 4 SEN00733-01

Troubleshooting by failure code (Display of code), Part 5 SEN00734-01

Troubleshooting by failure code (Display of code), Part 6 SEN00735-01

Troubleshooting by failure code (Display of code), Part 7 SEN00736-01

Troubleshooting by failure code (Display of code), Part 8 SEN00737-01

Troubleshooting by failure code (Display of code), Part 9 SEN00738-01

Troubleshooting by failure code (Display of code), Part 10 SEN00739-01

Troubleshooting of electrical system (E-mode) SEN00740-01

Troubleshooting of hydraulic and mechanical system (H-mode) SEN00741-00

Troubleshooting of engine (S-mode) SEN00742-01

50 Disassembly and assembly SEN00581-00

General information on disassembly and assembly SEN02022-00

Engine and cooling system SEN02023-00

Engine (SAA6D140E-5) SEN02024-00

Power train, Part 1 SEN02025-00

Power train, Part 2 SEN02026-00

Power train, Part 3 SEN02027-00

Brake system SEN02028-00

Undercarriage and frame SEN02029-00

Hydraulic system SEN02030-00

Work equipment SEN02031-00

Cab and its attachments SEN02032-00

Electrical system SEN02033-00

90 Diagrams and drawings SEN00582-01

Hydraulic diagrams and drawings SEN00714-01 q

Electrical diagrams and drawings SEN00715-00

SEN00701-05 00 Index and foreword

4WA500-6

Table of contents 1

00 Index and foreword

Index SEN00701-05

Composition of shop manual ................................................................................................... 2

Table of contents...................................................................................................................... 4

Foreword and general information SEN00702-02

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 ...................................................................... 20

How to read electric wire code................................................................................................. 23

Precautions when carrying out operation ................................................................................ 26

Method of disassembling and connecting push-pull type coupler ........................................... 29

Standard tightening torque table.............................................................................................. 32

Conversion table...................................................................................................................... 36

01 Specification

Specification and technical data SEN00703-01

Specification and technical data .................................................................................................. 2

Specification dimension drawing.............................................................................................. 2

Specifications........................................................................................................................... 3

Weight table............................................................................................................................. 6

Table of fuel, coolant and lubricants ........................................................................................ 8

10 Structure, function and maintenance standard

Engine and cooling system SEN00704-00

Engine and cooling system ......................................................................................................... 2

Cooling system ........................................................................................................................ 2

Engine mount and transmission mount ................................................................................... 5

Power train, Part 1 SEN00705-01

Power train, Part 1....................................................................................................................... 3

Power train............................................................................................................................... 3

Power train system diagram .................................................................................................... 4

Joint ......................................................................................................................................... 6

Drive shaft................................................................................................................................ 7

Power train piping diagram ......................................................................................................8

Torque converter...................................................................................................................... 10

Torque converter regulator valve ............................................................................................. 28

Transmission............................................................................................................................ 30

Transfer.................................................................................................................................... 50

Transmission control valve ......................................................................................................52

ECMV ...................................................................................................................................... 56

Main relief valve and torque converter relief valve .................................................................. 63

Lubrication relief valve ............................................................................................................. 65

Power train, Part 2 SEN00864-01

Power train, Part 2....................................................................................................................... 2

Torque converter oil cooler ...................................................................................................... 2

Torque converter oil filter ......................................................................................................... 3

Center support ......................................................................................................................... 6

Axle.......................................................................................................................................... 8

Differential................................................................................................................................ 10

Limited slip differential ............................................................................................................. 19

Final drive ................................................................................................................................ 24

00 Index and foreword SEN00701-05

WA500-6 5

Steering system SEN00706-01

Steering system........................................................................................................................... 2

Steering piping diagram........................................................................................................... 2

Steering column....................................................................................................................... 3

Steering control valve .............................................................................................................. 4

Steering valve .......................................................................................................................... 15

Stop valve ................................................................................................................................ 19

Joystick steering lever linkage (if equipped)............................................................................ 20

Steering cylinder ...................................................................................................................... 21

Emergency steering piping diagram (if equipped) ................................................................... 22

Diverter valve........................................................................................................................... 23

Brake system SEN00707-01

Brake system .............................................................................................................................. 2

Brake piping diagram............................................................................................................... 2

Brake valve.............................................................................................................................. 4

Slack adjuster .......................................................................................................................... 9

Accumulator charge valve ....................................................................................................... 12

PPC relief valve ....................................................................................................................... 16

Accumulator (for brake) ........................................................................................................... 18

Brake ....................................................................................................................................... 20

Parking brake control............................................................................................................... 23

Parking brake .......................................................................................................................... 24

Parking brake solenoid valve................................................................................................... 26

Emergency parking brake release valve ................................................................................. 28

Undercarriage and frame SEN00708-01

Undercarriage and frame ............................................................................................................ 2

Axle mount............................................................................................................................... 2

Center hinge pin ...................................................................................................................... 7

Hydraulic system, Part 1 SEN00709-01

Hydraulic system, Part 1 ............................................................................................................. 2

Hydraulic piping diagram ......................................................................................................... 2

Work equipment control lever linkage ..................................................................................... 4

Hydraulic tank.......................................................................................................................... 5

Cooling fan motor .................................................................................................................... 7

Cooling fan pump .................................................................................................................... 14

Steering pump ......................................................................................................................... 21

Work equipment hydraulic pump ............................................................................................. 32

Hydraulic system, Part 2 SEN00875-01

Hydraulic system, Part 2 ............................................................................................................. 2

Control valve............................................................................................................................ 2

CLSS ....................................................................................................................................... 16

Each function and operation of each valve.............................................................................. 21

Accumulator (for PPC circuit) .................................................................................................. 32

Work equipment electric lever ................................................................................................. 33

Work equipment SEN00710-01

Work equipment .......................................................................................................................... 2

Work equipment linkage ..........................................................................................................2

Bucket...................................................................................................................................... 6

Bucket positioner and boom kick-out....................................................................................... 8

Work equipment lubrication ..................................................................................................... 9

Cab and its attachments SEN00711-01

Cab and its attachments.............................................................................................................. 2

ROPS cab................................................................................................................................ 2

Air conditioner.......................................................................................................................... 4

Electrical system, Part 1 SEN00712-01

Electrical system, Part 1.............................................................................................................. 2

SEN00701-05 00 Index and foreword

6WA500-6

Machine monitor system..........................................................................................................2

Machine monitor ...................................................................................................................... 10

Electrical system, Part 2 SEN00713-01

Electrical system, Part 2.............................................................................................................. 2

Work equipment control system .............................................................................................. 2

Transmission controller system ............................................................................................... 36

Electrical system, Part 3 SEN00874-01

Electrical system, Part 3.............................................................................................................. 2

Electric transmission control .................................................................................................... 2

Engine starting circuit .............................................................................................................. 6

Engine stopping circuit............................................................................................................. 8

Preheating circuit ..................................................................................................................... 9

Parking brake circuit ................................................................................................................ 11

Backup and stop lamp circuits ................................................................................................. 16

Small lamp and head lamp circuits .......................................................................................... 18

Working lamp circuit ................................................................................................................ 19

Horn circuit............................................................................................................................... 20

Wiper and window washer circuits........................................................................................... 21

Sensor ..................................................................................................................................... 24

KOMTRAX terminal system (if equipped)................................................................................ 42

20 Standard value table

Standard service value table SEN00724-02

Standard service value table ....................................................................................................... 2

Standard service value table for engine................................................................................... 2

Standard service value table for chassis ................................................................................. 3

30 Testing and adjusting

Testing and adjusting, Part 1 SEN00725-02

Testing and adjusting, Part 1 ....................................................................................................... 3

Tools for testing, adjusting, and troubleshooting...................................................................... 3

Measuring engine speed ......................................................................................................... 6

Measuring exhaust gas color................................................................................................... 8

Measuring exhaust temperature .............................................................................................. 10

Adjusting valve clearance ........................................................................................................ 12

Testing compression pressure ................................................................................................. 13

Measuring blow-by pressure.................................................................................................... 15

Measuring engine oil pressure................................................................................................. 16

Measuring intake air (boost) pressure ..................................................................................... 17

Handling fuel system equipment.............................................................................................. 19

Releasing residual pressure in fuel system ............................................................................. 19

Testing fuel pressure................................................................................................................ 20

Testing return rate and leakage ............................................................................................... 21

Bleeding air from fuel circuit .................................................................................................... 24

Testing leakage in fuel system................................................................................................. 26

Handling reduced cylinder mode operation ............................................................................. 27

Handling no injection cranking operation................................................................................. 27

Handling controller voltage circuit............................................................................................ 28

Testing and adjusting alternator belt tension ........................................................................... 29

Testing and adjusting air conditioner compressor belt tension ................................................ 30

Adjusting transmission speed sensor ...................................................................................... 31

Measuring directional lever (Steering wheel specification) ...................................................... 33

Testing and adjusting power train oil pressure......................................................................... 34

Flushing procedure for torque converter and transmission hydraulic circuit............................ 47

Method of moving machine when transmission valve is broken.............................................. 50

00 Index and foreword SEN00701-05

WA500-6 7

Testing and adjusting, Part 2 SEN00726-02

Testing and adjusting, Part 2....................................................................................................... 3

Testing and adjusting steering stop valve................................................................................ 3

Testing and adjusting steering wheel....................................................................................... 5

Testing steering oil pressure.................................................................................................... 7

Bleeding air from steering cylinder circuit................................................................................ 10

Testing hydraulic drive fan ....................................................................................................... 11

Bleeding air from hydraulic drive fan circuit............................................................................. 14

Measuring brake pedal ............................................................................................................ 16

Measuring brake performance................................................................................................. 17

Testing and adjusting accumulator charge pressure ............................................................... 18

Testing wheel brake oil pressure ............................................................................................. 20

Measuring wear of wheel brake disc ....................................................................................... 22

Bleeding air from brake circuit .................................................................................................23

Releasing residual pressure in brake accumulator circuit ....................................................... 25

Testing parking brake performance ......................................................................................... 26

Measuring parking brake oil pressure ..................................................................................... 27

Testing wear of parking brake disc .......................................................................................... 30

Method of releasing parking brake manually ........................................................................... 31

Measuring and adjusting work equipment control lever .......................................................... 32

Testing and adjusting work equipment PPC oil pressure ........................................................ 33

Measuring work equipment oil pressure.................................................................................. 35

Bleeding air from work equipment circuit................................................................................. 41

Releasing residual pressure in work equipment circuit ........................................................... 42

Method of moving machine when removing operator cab (when splittable cab is used)......... 43

Testing and adjusting bucket positioner................................................................................... 44

Testing and adjusting lift arm position detecting lever ............................................................. 46

Checking proximity switch operation indication lamp .............................................................. 47

Procedure for testing diodes....................................................................................................48

Preparations for work on troubleshooting of electrical system ................................................ 49

Testing and adjusting, Part 3 SEN00727-01

Testing and adjusting, Part 3....................................................................................................... 2

Starting KOMTRAX terminal operations (if equipped) ............................................................. 2

Indicator lamps of KOMTRAX terminal (if equipped)............................................................... 8

Machine monitor-based adjustment at replacement, disassembly and assembly,

and additional installation for each sensor and controller ................................................ 11

Special functions of machine monitor (EMMS)........................................................................ 13

Testing and adjusting, Part 4 SEN00728-01

Testing and adjusting, Part 4....................................................................................................... 2

Special functions of machine monitor (EMMS)........................................................................ 2

Pm click inspection table ......................................................................................................... 40

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