Komatsu WA500-7 Wheel Loader Shop Manual VENBM46500 PDF DOWNLOAD

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Komatsu WA500-7 Wheel Loader Shop Manual VENBM46500 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-7 Wheel Loader Shop Manual VENBM46500 – PDF DOWNLOAD

Language : English
Pages : 2558
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA500-7 Wheel Loader Shop Manual VENBM46500 – PDF DOWNLOAD

• 10001 and up
• H62051 and up

00 Index and foreword . 3
Index . 4
Foreword, safety and general information 21
Important safety notice . 21
How to read the shop manual . 28
Explanation of terms for maintenance standard . 30
Handling equipment of fuel system devices . 32
Handling of intake system parts . 33
Handling of hydraulic equipment . 34
Method of disconnecting and connecting of push-pull type coupler 36
Handling of electrical equipment 39
How to read electric wire code 47
Precautions when performing operation . 50
Practical use of KOMTRAX 54
Standard tightening torque table 55
List of abbreviation 59
Conversion table 64
01 Specification 69
Table of contents . 70
Specifications 71
Specification drawing . 71
Specification . 73
Weight table 80
Table of fuel, coolant, and lubricants 82
10 Structure and function . 85
Table of contents . 86
Engine and cooling system . 88
Engine related parts 88
KVGT 90
EGR system piping drawing . 96
EGR system circuit diagram 98
EGR valve . 99
EGR cooler 101
KCCV layout drawing . 103
KCCV ventilator . 105
KDPF 107
Engine mount and transmission mount . 111
Joint . 112
Cooling system 113
Cooling fan pump 117
Cooling fan motor . 126
Power train . 133
Power train system 133
Drive shaft . 136
Power train piping drawing 137
Transmission control 138
Torque converter 140
Torque converter regulator valve 147
Transmission 149
Transfer 166
Transmission control valve 168
Forward and reverse clutch ECMV and gear speed clutch ECMV 171
Lockup clutch ECMV 178
Main relief valve, torque converter relief valve, and main flow selector valve 182
Torque converter oil cooler . 187
Center support 188
Lubricating oil relief valve 189
Axle 190
Differential 194
Final drive . 204
Steering system . 206
Layout of steering parts 206
Steering column . 207
Joystick steering lever linkage . 208
Steering pump . 209
Steering control valve 221
Orbitrol valve 231
Stop valve 237
Emergency steering piping diagram . 238
Diverter valve 239
Emergency steering pump . 243
Brake system 244
Layout of brake parts . 244
Charge valve 246
Brake valve . 252
Slack adjuster 257
Accumulator (for brake) . 260
Brake . 261
Parking brake control . 263
Parking brake . 264
Parking brake solenoid valve 266
Parking brake emergency release valve . 269
Undercarriage and frame . 270
Axle mount 270
Center hinge pin 271
Tire 273
Hydraulic system 275
Hydraulic component layout 275
Work equipment control 277
Hydraulic tank 279
Double type gear pump . 282
Work equipment pump . 283
Control valve . 304
CLSS 313
Hydraulic circuit diagram and names of valves . 317
Accumulator charge valve 329
Work equipment lock solenoid valve 333
Accumulator (for PPC circuit) . 334
Accumulator (for ECSS) 335
Work equipment 336
Work equipment linkage 336
Bucket 337
Bucket positioner and boom positioner . 339
Lubrication of work equipment . 340
Cab and its attachments . 342
ROPS cab 342
Electrical system . 343
Engine control system . 343
Preheating system . 345
Power mode selector circuit . 347
Engine output limit function 348
Automatic warm-up function 349
Parking brake control system 350
System operating lamp function 352
Battery disconnect switch function 354
Backup lamp and brake lamp 356
Clearance lamp and headlamp . 358
Working lamp 359
Horn circuit 360
Wiper and window washer circuit . 361
Transmission controller system 364
Work equipment control system . 389
Machine monitor system 409
Rear view monitor system 433
KOMTRAX system 436
System component parts 439
Sensor 473
Central lubrication system (CLS) . 497
Auto-grease pump . 497
Changing the lubrication interval times . 498
Operating the central lubrication system . 499
Display and control unit . 500
LED-display 500
Push buttons . 500
Three-digit LED display 501
Check central lubrication system, fill up grease . 502
20 Standard value tables 505
Table of contents . 506
Standard service value table 507
Standard value table for engine . 507
Standard value table for machine 509
Standard value table for electrical system 524
30 Testing and adjusting 539
Table of contents . 540
General information on testing and adjusting 542
Tools for testing and adjusting . 542
Sketch of tools for testing and adjusting . 547
Engine and cooling system . 549
Testing engine speed 549
Testing boost pressure 551
Testing exhaust gas temperature . 553
Testing exhaust gas color . 555
Testing and adjusting valve clearance . 558
Testing compression pressure 560
Testing blowby pressure . 563
Testing engine oil pressure . 565
Testing EGR valve and KVGT driving oil pressure . 567
Testing fuel pressure . 569
Testing fuel return rate and leakage 571
Bleeding air from fuel system . 575
Testing fuel circuit for leakage 577
Handling cylinder cutout mode operation . 578
Handling no injection cranking operation 579
Testing of KDPF and muffler stack for looseness and damage 580
Testing of installed condition of cylinder head and manifolds . 581
Testing engine piping for damage and looseness 582
Replacing and adjusting belt for alternator and air conditioner compressor 583
Procedures for cleaning fuel doser 584
Writing compensation values at replacement of injector and engine controller 587
Power train . 591
Adjusting transmission output speed sensor 591
Adjusting transmission input speed sensor . 592
Flushing procedure for torque converter and transmission hydraulic circuit 593
Retrieval of disabled machine due to transmission valve failure . 595
Testing oil leakage from axle final drive . 597
Testing drive shaft for looseness, backlash, and damage . 598
Testing and adjusting power train oil pressure 599
Steering system . 613
Testing directional lever . 613
Testing steering wheel 614
Testing work equipment control lever 616
Testing and adjusting steering circuit oil pressure . 618
Bleeding air from steering cylinder circuit. 621
Testing and adjusting steering stopper valve 622
Brake system 624
Testing brake pedal . 624
Testing and adjusting brake pedal linkage . 625
Adjustment procedure of transmission cut-off proximity switch of left brake pedal . 626
Testing braking performance . 627
Testing and adjusting of accumulator charge pressure 628
Testing wheel brake oil pressure 630
Testing lowering of wheel brake pressure 631
Testing wear of wheel brake disc 634
Bleeding air from wheel brake circuit . 635
Releasing remaining pressure in brake accumulator circuit . 637
Testing parking brake performance . 638
Testing parking brake oil pressure 639
Testing wear of parking brake disc 641
Method of releasing parking brake manually 642
Hydraulic system 644
Testing fan speed . 644
Testing fan pump circuit oil pressure . 645
Bleeding air from hydraulic fan circuit . 647
Testing work equipment EPC oil pressure . 649
Testing and adjusting work equipment oil pressure . 651
Bleeding air from work equipment circuit 657
Releasing remaining pressure from work equipment circuit 658
Checking of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas . 659
Work equipment 664
Testing and adjusting bucket position detection lever . 664
Testing and adjusting boom position detection lever . 665
Electrical system . 666
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor 666
Special functions of machine monitor 668
Adjusting rearview camera angle . 761
Handling voltage circuit of engine controller . 762
Handling battery disconnect switch 763
Testing diodes 764
Pm clinic . 765
Pm Clinic service . 765
Check sheet . 766
40 Troubleshooting 773
Table of contents . 774
General information on troubleshooting 784
Troubleshooting points 784
Sequence of events in troubleshooting . 786
Check before troubleshooting 788
Inspection procedure before troubleshooting . 790
Preparation work for troubleshooting of electrical system . 807
Classification and procedures for troubleshooting . 813
Symptom and troubleshooting numbers . 816
Information in troubleshooting table 819
Connector list and layout . 821
Connector contact identification 836
T-branch box and T-branch adapter table . 872
Fuse location table . 878
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement . 881
Precautions on troubleshooting of machine monitor . 884
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit . 886
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) . 891
Fabrication of short-circuit connector (for CA1883 and CA3135) 892
Failure codes table . 893
Troubleshooting by failure code (Display of code) . 908
Failure code [1500L0] Double Engagement of T/M Clutches . 908
Failure code [15B0NX] Transmission Oil Filter Clogging 909
Failure code [15SAL1] Release Trouble of ECMV (Forward) . 910
Failure code [15SALH] Malfunction of ECMV (Forward) . 912
Failure code [15SBL1] Release Trouble of ECMV (Reverse) . 914
Failure code [15SBLH] Malfunction of ECMV (Reverse) . 916
Failure code [15SEL1] Release Trouble of ECMV (1st clutch) 918
Failure code [15SELH] Malfunction of ECMV (1st) . 920
Failure code [15SFL1] Release Trouble of ECMV (2nd) . 922
Failure code [15SFLH] Malfunction of ECMV (2nd) . 924
Failure code [15SGL1] Release Trouble of ECMV (3rd) . 926
Failure code [15SGLH] Malfunction of ECMV (3rd) . 928
Failure code [15SHL1] Release Trouble of ECMV (4th) . 930
Failure code [15SHLH] Malfunction of ECMV (4th) . 932
Failure code [2F00MA] Failure of Parking Brake Circuit 934
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 937
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) . 939
Failure code [879AKA] A/C Inner Sensor Open Circuit . 941
Failure code [879AKB] A/C Inner Sensor Short Circuit 942
Failure code [879BKA] A/C Outer Sensor Open Circuit . 943
Failure code [879BKB] A/C Outer Sensor Short Circuit 944
Failure code [879CKA] Ventilating Sensor Open Circuit . 945
Failure code [879CKB] Ventilating Sensor Short Circuit 946
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit . 947
Failure code [879EMC] Ventilation Damper Abnormality 948
Failure code [879FMC] Air Mix Damper Abnormality 949
Failure code [989A00] Engine Overrun Prevention Activated . 950
Failure code [989L00] Engine Controller Lock Caution 1 951
Failure code [989M00] Engine Controller Lock Caution 2 952
Failure code [989N00] Engine Controller Lock Caution 3 953
Failure code [A1U0N3] HC Desorb Request 1 . 954
Failure code [A1U0N4] HC Desorb Request 2 . 956
Failure code [AA10NX] Air Cleaner Clogging 958
Failure code [B@BAZG] Eng Oil Press Low . 960
Failure code [B@BCNS] Eng Water Overheat 961
Failure code [B@BCZK] Eng Water Level Low . 962
Failure code [B@CENS] T/C Oil Temp. Overheat 964
Failure code [B@HANS] HYD Oil Temp. Overheat 965
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 966
Failure code [CA122] Chg Air Press Sensor High Error 967
Failure code [CA123] Chg Air Press Sensor Low Error . 969
Failure code [CA131] Throttle Sensor High Error . 971
Failure code [CA132] Throttle Sensor Low Error 973
Failure code [CA135] Eng Oil Press Sensor High Error 975
Failure code [CA141] Eng Oil Press Sensor Low Error . 977
Failure code [CA144] Coolant Temp Sens High Error . 979
Failure code [CA145] Coolant Temp Sens Low Error 981
Failure code [CA153] Chg Air Temp Sensor High Error . 983
Failure code [CA154] Chg Air Temp Sensor Low Error 985
Failure code [CA187] Sensor 2 Supply Volt Low Error . 987
Failure code [CA221] Ambient Press Sens High Error 989
Failure code [CA222] Ambient Press Sens Low Error . 991
Failure code [CA227] Sensor 2 Supply Volt High Error 993
Failure code [CA234] Eng Overspeed 994
Failure code [CA238] Ne Speed Sensor Supply Volt Error 995
Failure code [CA239] Ne Speed Sens Supply Volt High Error . 996
Failure code [CA271] IMV/PCV1 Short Error . 997
Failure code [CA272] IMV/PCV1 Open Error 998
Failure code [CA273] PCV2 Short Error . 999
Failure code [CA274] PCV2 Open Error 1000
Failure code [CA322] Inj #1(L#1) Open/Short Error .1001
Failure code [CA323] Inj #5(L#5) Open/Short Error .1003
Failure code [CA324] Inj #3(L#3) Open/Short Error .1005
Failure code [CA325] Inj #6(L#6) Open/Short Error .1007
Failure code [CA331] Inj #2(L#2) Open/Short Error .1009
Failure code [CA332] Inj #4(L#4) Open/Short Error .1011
Failure code [CA343] ECM Critical Internal Failure 1013
Failure code [CA351] Injectors Drive Circuit Error 1014
Failure code [CA352] Sensor 1 Supply Volt Low Error .1015
Failure code [CA356] Mass Air Flow Sensor High Error 1017
Failure code [CA357] Mass Air Flow Sensor Low Error .1019
Failure code [CA386] Sensor 1 Supply Volt High Error 1021
Failure code [CA431] Idle Validation Sw Error .1022
Failure code [CA432] Idle Validation Process Error 1025
Failure code [CA441] Battery Voltage Low Error 1028
Failure code [CA442] Battery Voltage High Error .1030
Failure code [CA449] Rail Press Very High Error .1031
Failure code [CA451] Rail Press Sensor High Error .1032
Failure code [CA452] Rail Press Sensor Low Error 1034
Failure code [CA515] Rail Press Sens Sup Volt High Error 1036
Failure code [CA516] Rail Press Sens Sup Volt Low Error .1038
Failure code [CA553] Rail Press High Error 1040
Failure code [CA555] Crankcase Press High Error 2 .1041
Failure code [CA556] Crankcase Press High Error 3 .1042
Failure code [CA559] Rail Press Low Error .1043
Failure code [CA595] Turbo Speed High Error 2 .1047
Failure code [CA687] Turbo Speed Low Error 1048
Failure code [CA689] Eng Ne Speed Sensor Error 1050
Failure code [CA691] Intake Air Temp Sens High Error 1052
Failure code [CA692] Intake Air Temp Sens Low Error .1054
Failure code [CA697] ECM Internal Temp Sensor High Error 1056
Failure code [CA698] ECM Int Temp Sensor Low Error 1057
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1058
Failure code [CA778] Eng Bkup Speed Sensor Error 1059
Failure code [CA1117] Persistent Data Lost Error 1061
Failure code [CA1664] KDOC Malfunction 1062
Failure code [CA1691] Regeneration Ineffective 1065
Failure code [CA1695] Sensor 5 Supply Volt High Error .1068
Failure code [CA1696] Sensor 5 Supply Volt Low Error 1069
Failure code [CA1843] Crankcase Press Sens High Error .1071
Failure code [CA1844] Crankcase Press Sens Low Error 1073
Failure code [CA1879] KDPF Delta P Sensor High Error 1075
Failure code [CA1881] KDPF Delta P Sensor Low Error .1077
Failure code [CA1883] KDPF Delta P Sens In Range Error 1079
Failure code [CA1921] KDPF Soot Load High Error 1 .1082
Failure code [CA1922] KDPF Soot Load High Error 2 .1085
Failure code [CA1923] Dosing Fuel Valve 1 High Error 1090
Failure code [CA1924] Dosing Fuel Valve 1 Low Error .1092
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error 1095
Failure code [CA1927] Dosing Fuel Press Sens High Error .1097
Failure code [CA1928] Dosing Fuel Press Sens Low Error 1099
Failure code [CA1942] Crankcase Press Sens In Range Error .1101
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error .1102
Failure code [CA1977] Fuel Doser Open/Short Error .1104
Failure code [CA1993] KDPF Delta Pressure Low Error .1106
Failure code [CA2185] Throt Sensor Sup Volt High Error 1109
Failure code [CA2186] Throt Sensor Sup Volt Low Error .1111
Failure code [CA2249] Rail Press Very Low Error .1113
Failure code [CA2265] Fuel Feed Pump Open Error .1114
Failure code [CA2266] Fuel Feed Pump Short Error 1116
Failure code [CA2271] EGR Valve Pos Sens High Error .1118
Failure code [CA2272] EGR Valve Pos Sens Low Error 1120
Failure code [CA2349] EGR Valve Solenoid Open Error .1122
Failure code [CA2353] EGR Valve Solenoid Short Error 1124
Failure code [CA2357] EGR Valve Servo Error .1126
Failure code [CA2381] KVGT Pos Sens High Error 1127
Failure code [CA2382] KVGT Pos Sens Low Error .1129
Failure code [CA2383] KVGT Solenoid Open Error 1131
Failure code [CA2386] KVGT Solenoid Short Error .1133
Failure code [CA2387] KVGT Servo Error 1135
Failure code [CA2555] Grid Htr Relay Volt Low Error .1136
Failure code [CA2556] Grid Htr Relay Volt High Error 1138
Failure code [CA2637] KDOC Face Plugging 1140
Failure code [CA2639] Manual Stationary Regeneration Request 1142
Failure code [CA2732] Dosing Fuel Valve 2 High Error 1145
Failure code [CA2733] Dosing Fuel Valve 2 Low Error .1147
Failure code [CA2741] Dosing Fuel Valve Swap Error 1149
Failure code [CA2765] Inj Trim Data Error .1151
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error .1152
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 1155
Failure code [CA3133] KDPF Outlet Press Sens High Error .1160
Failure code [CA3134] KDPF Outlet Press Sens Low Error 1162
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .1164
Failure code [CA3167] Fuel Doser Degradation 1167
Failure code [CA3251] KDOC Inlet Temp High Error 1170
Failure code [CA3253] KDOC Temp Error – Non Regeneration 1173
Failure code [CA3254] KDOC Outlet Temp High Error 1 .1176
Failure code [CA3255] KDPF Temp Error – Non Regeneration 1179
Failure code [CA3256] KDPF Outlet Temp High Error 1 .1183
Failure code [CA3311] KDOC Outlet Temp High Error 2 .1186
Failure code [CA3312] KDPF Outlet Temp High Error 2 .1189
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1192
Failure code [CA3314] KDOC Inlet Temp Sens High Error .1195
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .1198
Failure code [CA3316] KDOC Outlet Temp Sens Low Error .1202
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1205
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1208
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1211
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .1214
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1216
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1219
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error .1221
Failure code [D160KA] Disconnection of Backup Lamp Relay Output .1223
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output 1225
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .1227
Failure code [D191KA] Disconnection of Neutral Output Relay .1229
Failure code [D191KB] Ground Fault of Neutral Output Relay 1231
Failure code [D191KY] Hot Short of Neutral Output Relay .1233
Failure code [D192KA] Disconnection of ECSS Solenoid 1235
Failure code [D192KB] Ground Fault of ECSS Solenoid .1237
Failure code [D192KY] Hot Short of ECSS Solenoid 1239
Failure code [D193KA] Disconnection of J/S Solenoid Cut Relay .1240
Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay 1242
Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay .1244
Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay .1246
Failure code [D19JKZ] Personal Code Relay Abnormality .1248
Failure code [D1E6KA] Disconnection of Parking Brake Relay 1250
Failure code [D1E6KB] Ground Fault of Parking Brake Relay .1252
Failure code [D1E6KY] Hot Short of Parking Brake Relay 1254
Failure code [D5ZHKA] Failure of Key SW C Signal 1256
Failure code [D5ZHKB] Key SW C Signal Short Circuit .1258
Failure code [D5ZHKZ] Failure of Key SW C Signal 1260
Failure code [D5ZHL6] Disconnection of Key SW C .1262
Failure code [D811MC] KOMTRAX Error .1264
Failure code [D862KA] GPS Antenna Open Circuit 1265
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .1266
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1268
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .1270
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .1271
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 1273
Failure code [DAF0MB] Monitor ROM Abnormality .1274
Failure code [DAF0MC] Monitor Error .1275
Failure code [DAF3KK] Controller Power Source Low (MON) .1276
Failure code [DAF8KB] Camera Power Supply Short Circuit .1278
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 1279
Failure code [DAFGMC] GPS Module Error 1281
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) .1282
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 1284
Failure code [DAFQKR] CAN2 Discon (Monitor) .1286
Failure code [DAQ0KK] Controller Power Source Low (T/M) .1287
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 1290
Failure code [DAQ0MC] T/M Con Error .1291
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .1292
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) .1294
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .1297
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 1299
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .1300
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 1302
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 1304
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 1305
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) .1306
Failure code [DAZ9KQ] A/C Model Selection Abnormality .1307
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1308
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1309
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1314
Failure code [DB90KK] Drop in BBC Controller Main Power Source 1319
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) 1322
Failure code [DB90MC] BBC Error .1323
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) .1324
Failure code [DB92KK] Solenoid Power Source Low (BBC) .1326
Failure code [DB95KX] Failure of 5 V Power Source 1 .1328
Failure code [DB96KX] Failure of 5 V Power Source 2 .1332
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) 1336
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) .1337
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) 1339
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .1341
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .1342
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) .1343
Failure code [DBE5KX] Failure of 5V Power Source 1344
Failure code [DBE6KX] Failure of 24 V Power Source 1346
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 1348
Failure code [DDA8KY] Hot Short of Throttle Lock Set SW .1352
Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW 1354
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 1356
Failure code [DDB6L4] Neutral Signal Malfunction 1358
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch .1361
Failure code [DDE5KA] Failure of Emergency Steering Signal 1365
Failure code [DDK3KA] FNR SW Input Signal Disconnection .1367
Failure code [DDK3KB] FNR SW Input Signal Short Circuit .1372
Failure code [DDK4KA] J/S FNR Input Signal Disconnection 1376
Failure code [DDK4KB] J/S FNR Input Signal Short Circuit 1379
Failure code [DDK5L4] Failure of J/S Shift Up/Down SW .1381
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 1383
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 1386
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .1388
Failure code [DDT0L4] Failure of Shift Mode Select SW .1392
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal .1396
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal .1400
Failure code [DDW9LD] Ground Fault of Kickdown Switch .1404
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW .1408
Failure code [DF10KA] Disconnection of Shift Lever Input 1412
Failure code [DF10KB] Ground Fault of Shift Lever Input .1415
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor .1417
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor 1419
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor 1421
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor 1423
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .1424
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor .1426
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor 1428
Failure code [DH21KA] Failure of Loader Pump Press. Sensor 1430
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit .1432
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit .1434
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor .1436
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor .1438
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. .1440
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor .1442
Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit 1444
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .1445
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor 1448
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor 1451
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit .1453
Failure code [DHT8ZG] Steering Oil Pressure Low .1455
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1456
Failure code [DK55KA] Failure of FNR Lever Potentio .1458
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit .1460
Failure code [DK55L5] Failure of FNR Lever Potentio .1462
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) .1463
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) .1468
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .1473
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) 1480
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) 1486
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) .1491
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) .1496
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .1501
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) 1508
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) 1513
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 1518
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 1523
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 1527
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) .1533
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) .1538
Failure code [DK5FKA] Failure of J/S Lever Potentio (Main) 1542
Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main) 1545
Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree 1548
Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub) .1552
Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub) .1555
Failure code [DKA0KA] Failure of Boom Angle Sensor 1558
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 1560
Failure code [DKA0L0] Boom Angle Sensor Dislocation .1562
Failure code [DKA1KA] Failure of Bucket Angle Sensor 1564
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit 1566
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor .1568
Failure code [DLF1LC] Failure of T/M Input Speed Sensor .1570
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1572
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1574
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) 1576
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .1578
Failure code [DPQ1KR] LIN Discon (Switch Panel) .1580
Failure code [DPQ2KR] LIN Discon (LED Unit) .1583
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1586
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1589
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .1591
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .1595
Failure code [DV00KB] Ground Fault of Buzzer Output .1599
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. 1601
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. .1602
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. 1603
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve .1604
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve .1605
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) 1606
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) .1608
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) 1610
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) 1612
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) .1614
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) 1616
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) .1618
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 1620
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) .1622
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) .1624
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) 1626
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) .1628
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid .1630
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. 1631
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .1633
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 1634
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid .1636
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 1638
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) .1640
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 1644
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) .1648
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) .1652
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 1656
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) .1660
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. .1664
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. 1666
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. .1668
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid .1670
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid 1672
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid .1674
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) .1675
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 1677
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .1679
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 1681
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .1683
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 1685
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 1687
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .1689
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 1691
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 1693
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .1694
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 1696
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 1698
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) .1700
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 1702
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) 1704
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) .1706
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) 1708
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) 1710
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .1712
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) 1714
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) .1716
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 1718
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .1720
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) .1722
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 1724
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) .1726
Failure code [DXHLKA] Disconnection of J/S Right EPC Solenoid .1728
Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid 1730
Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid .1732
Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid 1734
Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid .1736
Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid 1738
Failure code [LA00L3] Failure of Fan Reverse 1740
Troubleshooting of electrical system (E-mode) .1741
E-1 Engine does not start (Engine does not crank) .1741
E-2 Manual preheating system does not work 1748
E-3 Automatic preheating system does not work .1751
E-4 While preheating is working, preheating monitor does not light up .1753
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 1755
E-6 LCD unit on machine monitor displays nothing 1758
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .1760
E-8 LCD on machine monitor does not display properly 1762
E-9 Meter unit display on machine monitor is abnormal .1764
E-10 Night lighting lamp of meter unit on machine monitor is abnormal .1767
E-11 Caution LED on machine monitor is abnormal .1770
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly .1772
E-13 Two switches operation of switch panel on machine monitor does not function 1774
E-14 Switch panel buzzer of machine monitor is abnormal .1777
E-15 Rearview monitor does not light up or backlight flickers .1779
E-16 Rearview monitor images are not displayed clearly 1782
E-17 Rearview monitor brightness cannot be adjusted .1785
E-18 Night lighting lamp of rearview monitor is abnormal 1788
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly .1790
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .1791
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light 1795
E-22 Air cleaner clogging indicator lamp does not light .1797
E-23 Radiator coolant level caution lamp does not light .1798
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light 1800
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light 1802
E-26 Fuel level gauge does not indicate correct level .1803
E-27 Seat belt caution lamp indication is abnormal 1805
E-28 Horn does not sound 1806
E-29 Horn does not stop sounding 1808
E-30 Alarm buzzer does not sound 1809
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 1810
E-32 Kickdown does not work when kickdown switch is turned ON .1811
E-33 The hold switch does not work when it is pressed .1813
E-34 Transmission is always shifted to Neutral, or the brake drags when parking brake applies and FR drive is selected 1815
E-35 Transmission cut-off mode is not selected or not released 1818
E-36 Transmission cut-off setting cannot be released 1820
E-37 FNR switch mode is not selected or not released 1822
E-38 When operating engine mode selector switch, engine mode selector function does not operate properly 1824
E-39 Flow of loader pump does not increase from the minimum rate 1826
E-40 ECSS function cannot be selected or cannot be released .1827
E-41 None of headlamp, clearance lamp, and tail lamp lights .1829
E-42 Clearance lamp and tail lamp do not light up or go out .1831
E-43 Both High and Low beams of headlamp do not light up or go out 1834
E-44 Low beam of headlamp does not light up or go out .1838
E-45 High beam of headlamp does not light up or go out 1840
E-46 Front working lamp does not light up or go out .1842
E-47 Rear working lamp does not light up or go out 1845
E-48 All of turn signal lamps and hazard lamps do not light up or go out 1848
E-49 Turn signal lamps do not light up or go out 1851
E-50 Hazard lamp does not light up or go out 1854
E-51 Brake lamp does not light up or stays lighted 1857
E-52 Backup lamp does not light or continues to light .1860
E-53 Backup buzzer does not sound or continues to sound .1863
E-54 Front wiper does not operate .1865
E-55 Rear wiper does not operate 1868
E-56 Window washer does not operate .1871
E-57 Fuel feed pump does not operate or stop automatically 1874
E-58 KOMTRAX system does not operate properly .1876
Troubleshooting of hydraulic and mechanical system (H-mode) .1878
Information described in troubleshooting table (H-mode) .1878
System chart of hydraulic and mechanical systems 1879
Failure mode and cause table 1883
H-1 Machine does not start 1892
H-2 Torque converter lockup clutch is not disengaged (engine stalls) 1895
H-3 Torque converter lockup clutch is not engaged .1896
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift .1897
H-5 Large shock is made when machine starts or gear is shifted 1900
H-6 Machine starts or gear speed shifts with long time lag 1902
H-7 Torque converter oil temperature is high 1904
H-8 Machine does not turn .1906
H-9 Turning response is poor 1910
H-10 Steering wheel is heavy to turn 1914
H-11 Machine sways or large shocks are made while machine turns .1915
H-12 Turning radius differs between right and left turns 1919
H-13 Wheel brakes do not work or are weak .1920
H-14 Wheel brakes are not released or drag 1922
H-15 Parking brake does not work or it is weak 1923
H-16 Parking brake is not released or drags (including emergency release system) 1924
H-17 Boom does not rise .1925
H-18 Boom moves slow or boom lacks lifting force 1927
H-19 Rising boom slows down at certain height .1929
H-20 Lift cylinders do not serve to hold bucket on ground .1930
H-21 Hydraulic drift of boom is large .1931
H-22 Boom moves up and down during operation 1932
H-23 Bucket does not tilt back 1933
H-24 Bucket moves slow or bucket lacks tilt-back force 1935
H-25 Bucket decelerates during tilt-back operation 1937
H-26 Bucket cylinder does not hold bucket on ground .1938
H-27 Hydraulic drift of bucket is large .1939
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) 1940
H-29 Boom and bucket control levers do not move smoothly and are heavy to move 1941
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall .1942
H-31 Large shocks are made when work equipment starts to move and stops .1943
H-32 When certain work equipment stalls hydraulically, other work equipment moves .1945
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces .1946
H-34 Fan speed is abnormal (too high or low, or fan does not rotate) 1947
H-35 Unusual noise is heard from around fan .1948
Troubleshooting of engine (S-mode) 1949
Information mentioned in troubleshooting table (S mode) .1949
S-1 When starting switch is turned to START position, engine is not cranked .1950
S-2 The engine cranks but exhaust smoke does not come out .1951
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 1952
S-4 Engine startability is poor .1953
S-5 Engine does not pick-up smoothly 1956
S-6 Engine stops during operation .1959
S-7 Engine runs rough or is unstable 1961
S-8 Engine lacks power 1962
S-9 KDPF gets clogged in a short time .1964
S-10 Engine oil consumption is excessive 1966
S-11 Engine oil becomes contaminated early 1967
S-12 Fuel consumption is excessive 1968
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .1969
S-14 Oil pressure drops .1970
S-15 Fuel mixes into engine oil .1971
S-16 Water mixes into engine oil (milky) 1972
S-17 Coolant temperature rises too high (overheating) .1973
S-18 Unusual noise is heard .1974
S-19 Vibration is excessive .1975
S-20 Air cannot be bled from fuel circuit .1976
S-21 Active regeneration is executed frequently .1977
S-22 Active regeneration takes a long time 1978
S-23 White smoke is exhausted during active regeneration 1979
Troubleshooting of Central Lubrication System (CLS) 1981
Trouble 1981
Low level indicator 1981
Fault Messages .1981
Troubleshooting FPS 1982
Troubleshooting 1983
Pump Faults 1983
Pump faults 1984
Pump element .1984
Replace pump element .1985
Check power supply .1985
Changing the control unit 1985
Troubleshooting – grease system faults .1986
Venting of the system 1987
General assembly advice 1988
50 Disassembly and assembly .1989
Table of contents .1990
General information on disassembly and assembly .1992
How to read this manual .1992
Coating materials list 1994
Special tools list 1998
Sketches of special tools .2002
Engine and cooling system .2011
Removal and installation of supply pump assembly 2011
Removal and installation of injector assembly .2017
Removal and installation of cylinder head assembly 2037
Removal and installation of engine hood assembly 2058
Removal and installation of radiator core assembly 2062
Removal and installation of aftercooler .2065
Removal and installation of hydraulic oil cooler 2068
Removal and installation of power train oil cooler assembly .2072
Removal and installation of engine assembly .2074
Removal and installation of engine front oil seal .2081
Removal and installation of engine rear oil seal 2084
Removal and installation of cooling fan and fan motor assembly 2089
Removal and installation of KDPF assembly .2091
Disassembly and assembly of KDPF assembly .2094
Removal and installation of KCCV assembly .2102
Removal and installation of KVGT assembly .2104
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .2108
Removal and installation of air cleaner assembly 2112
Removal and installation of air conditioner compressor assembly .2114
Removal and installation of air conditioner condenser assembly 2116
Removal and installation of belt for alternator and air conditioner compressor 2118
Removal and installation of fuel tank assembly 2120
Power train .2122
Removal and installation of power train unit assembly .2122
Disconnection and connection of power train unit assembly .2127
Disassembly and assembly of input transfer assembly .2131
Disassembly and assembly of torque converter assembly .2137
Disassembly and assembly of transmission assembly .2150
Disassembly and assembly of transfer and parking brake assembly .2177
Removal and installation of front differential assembly .2193
Disassembly and assembly of differential assembly (with LSD) 2195
Disassembly and assembly of differential assembly (without LSD) .2209
Removal and installation of front axle assembly .2220
Removal and installation of rear axle assembly 2222
Disassembly and assembly of final drive assembly (front and rear) .2224
Steering system .2230
Removal and installation of steering valve assembly .2230
Brake system 2232
Removal and installation of brake assembly (front and rear) .2232
Disassembly and assembly of brake assembly (front and rear) .2234
Disassembly and assembly of slack adjuster assembly .2240
Disassembly and assembly of brake accumulator charge valve assembly .2241
Undercarriage and frame .2242
Removal and installation of center hinge pin 2242
Removal and installation of large counterweight assembly 2249
Removal and installation of small counterweight assembly 2251
Hydraulic system 2252
Removal and installation of hydraulic tank assembly .2252
Removal and installation of work equipment pump assembly 2255
Removal and installation of steering and power train pump assembly 2257
Removal and installation of cooling fan pump assembly .2259
Removal and installation of work equipment control valve assembly .2261
Disassembly and assembly of work equipment control valve assembly .2264
Removal and installation of diverter valve assembly .2267
Disassembly and assembly of steering cylinder assembly 2269
Disassembly and assembly of work equipment cylinder assembly 2272
Work equipment 2277
Removal and installation of work equipment assembly .2277
Cab and its attachments .2281
Removal and installation of operator’s cab assembly (separate cab and floor specification) 2281
Removal and installation of operator’s cab glass (stuck window glass) .2285
Removal and installation of operator’s seat assembly 2293
Removal and installation of seat belt .2295
Removal and installation of air conditioner unit assembly .2296
Electrical system .2301
Removal and installation of machine monitor assembly 2301
Removal and installation of work equipment controller assembly 2302
Removal and installation of rear view monitor assembly 2304
Removal and installation of engine controller assembly 2305
Removal and installation of transmission controller assembly 2307
Removal and installation of monitor controller assembly .2308
Removal and installation of mass air flow and temperature sensor 2310
Removal and installation of KOMTRAX terminal assembly .2311
Troubleshooting of Central Lubrication System (CLS) 1981
Trouble 1981
Low level indicator 1981
Fault Messages .1981
Troubleshooting FPS 1982
Troubleshooting 1983
Pump Faults 1983
Pump faults 1984
Pump element .1984
Replace pump element .1985
Check power supply .1985
Changing the control unit 1985
Troubleshooting – grease system faults .1986
Venting of the system 1987
General assembly advice 1988
60 Maintenance standard .2313
Table of contents .2314
Engine and cooling system .2315
Engine mount and transmission mount .2315
Joint .2317
Cooling fan pump 2318
Servo valve .2320
Cooling fan motor .2321
Power train .2323
Drive shaft .2323
Torque converter 2324
Torque converter regulator valve 2328
Transmission 2329
Transmission control valve 2336
Forward and reverse clutch ECMV and gear speed clutch ECMV 2337
Lockup clutch ECMV 2338
Main relief valve, torque converter relief valve, and main flow selector valve 2339
Center support 2341
Lubricating oil relief valve 2342
Axle 2343
Differential 2345
Final drive .2351
Steering system .2353
Steering column .2353
Steering pump .2354
Steering control valve 2358
Steering cylinder .2359
Diverter valve 2361
Emergency steering pump .2362
Brake system 2363
Charge valve 2363
Brake valve .2365
Slack adjuster 2366
Accumulator (for brake) .2367
Brake .2368
Parking brake .2370
Parking brake solenoid valve 2372
Undercarriage and frame .2373
Axle mount 2373
Center hinge pin 2376
Hydraulic system 2378
Hydraulic tank 2378
Double type gear pump .2379
Work equipment pump .2381
Control valve .2383
Accumulator charge valve 2392
Work equipment 2393
Work equipment linkage 2393
Bucket 2396
Bucket positioner and boom positioner .2398
Work equipment cylinder .2399
80 Appendix .2401
Table of contents .2402
Air conditioner components 2403
Precautions for refrigerant .2403
Air conditioner component .2404
Configuration and function of refrigeration cycle .2406
Outline of refrigeration cycle 2407
Air conditioner unit 2409
Dual pressure switch 2414
Air conditioner controller 2415
Compressor 2416
Condenser .2417
Receiver drier 2418
Sunlight sensor .2420
Outer temperature sensor (outside air temperature sensor) .2421
Procedure for testing and troubleshooting .2422
Circuit diagram and arrangement of connector pins .2424
Parts and connectors layout .2426
Testing with self-diagnosis function 2431
Testing temperature control system 2434
Testing vent (mode) changeover 2436
Testing FRESH/RECIRC air changeover .2438
Check evaporator temperature sensor .2440
Testing relays 2442
Troubleshooting chart 1 .2444
Troubleshooting chart 2 .2445
Information in troubleshooting table 2447
Failure code list related to air conditioner 2448
Failure code [879AKA] A/C Inner Sensor Open Circuit .2449
Failure code [879AKB] A/C Inner Sensor Short Circuit 2451
Failure code [879BKA] A/C Outer Sensor Open Circuit .2453
Failure code [879BKB] A/C Outer Sensor Short Circuit 2455
Failure code [879CKA] Ventilating Sensor Open Circuit .2457
Failure code [879CKB] Ventilating Sensor Short Circuit 2459
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .2461
Failure code [879EMC] Ventilation Damper Abnormality 2463
Failure code [879FMC] Air Mix Damper Abnormality 2466
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 2469
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) .2472
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2475
A-4 Troubleshooting for FRESH/RECIRC air changeover .2478
Troubleshooting with gauge pressure .2480
Connection of service tool 2483
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .2485
Handling of compressor oil 2487
90 Diagrams and drawings 2489
Table of contents .2490
Hydraulic circuit diagram .2491
Symbols in hydraulic circuit diagram 2491
Brake hydraulic circuit diagram .2497
Hydraulic circuit diagram 2499
Electric circuit diagram 2501
Symbols in electric circuit diagram .2501
Electrical circuit diagram (1/13) 2505
Electrical circuit diagram (2/13) 2507
Electrical circuit diagram (3/13) 2509
Electrical circuit diagram (4/13) 2511
Electrical circuit diagram (5/13) 2513
Electrical circuit diagram (6/13) 2515
Electrical circuit diagram (7/13) 2517
Electrical circuit diagram (8/13) 2519
Electrical circuit diagram (9/13) 2521
Electrical circuit diagram (10/13) .2523
Electrical circuit diagram (11/13) .2525
Electrical circuit diagram (12/13) .2527
Electrical circuit diagram (13/13) .2529
Electrical circuit diagram of floor (1/7) (EU specification) .2531
Electrical circuit diagram of floor (2/7) (EU specification) .2533
Electrical circuit diagram of floor (3/7) (EU specification) .2535
Electrical circuit diagram of floor (4/7) (EU specification) .2537
Electrical circuit diagram of floor (5/7) (EU specification) .2539
Electrical circuit diagram of floor (6/7) (EU specification) .2541
Electrical circuit diagram of floor (7/7) (EU specification) .2543
INDEX 2545

DESCRIPTION:

Komatsu WA500-7 Wheel Loader Shop Manual VENBM46500 – PDF DOWNLOAD

• 10001 and up
• H62051 and up

How to read the shop manual 
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

G.B 31/12/24