Komatsu ecot3 WA500-6 Install guide

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

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WA500-6 1
SEN00701-19
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
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SEN00701-19 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 Tab 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 SEN00236-19
00 Index and foreword SEN00575-19
Index SEN00701-19 q
Foreword and general information SEN00702-05
01 Specification SEN00576-03
Specification and technical data SEN00703-03 q
10 Structure, function and maintenance standard SEN00577-06
Engine and cooling system SEN00704-01
Power train, Part 1 SEN00705-03
Power train, Part 2 SEN00864-02
Steering system SEN00706-03
Brake system SEN00707-02
Undercarriage and frame SEN00708-01
Hydraulic system, Part 1 SEN00709-02
Hydraulic system, Part 2 SEN00875-01
Work equipment SEN00710-02
Cab and its attachments SEN00711-01
Electrical system, Part 1 SEN00712-04
Electrical system, Part 2 SEN00713-02
Electrical system, Part 3 SEN00874-02
20 Standard value table SEN00578-05
Standard service value table SEN00724-05
30 Testing and adjusting SEN00579-11
Testing and adjusting, Part 1 SEN00725-07
Testing and adjusting, Part 2 SEN00726-06
Testing and adjusting, Part 3 SEN00727-05
Testing and adjusting, Part 4 SEN00728-07
40 Troubleshooting SEN00580-07
General information on troubleshooting SEN00729-02
Troubleshooting by failure code (Display of code), Part 1 SEN00730-01
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00 Index and foreword SEN00701-19
WA500-6 3
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
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) SEN00740-02
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00741-00
Troubleshooting of engine (S-mode) SEN00742-03
50 Disassembly and assembly SEN00581-06
General information on disassembly and assembly SEN02022-03
Engine and cooling system, Part 1 SEN02023-03
Engine and cooling system, Part 2 SEN02024-04
Power train, Part 1 SEN02025-04
Power train, Part 2 SEN02026-04
Power train, Part 3 SEN02027-04
Brake system SEN02028-00
Undercarriage and frame SEN02029-04
Hydraulic system SEN02030-04
Work equipment SEN02031-01
Cab and its attachments SEN02032-04
Electrical system SEN02033-03
90 Diagrams and drawings SEN00582-07
Hydraulic diagrams and drawings SEN00714-05 q
Electrical diagrams and drawings SEN00715-03
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SEN00701-19 00 Index and foreword
4WA500-6
Table of contents 1
00 Index and foreword
Index SEN00701-19
Composition of shop manual................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00702-05
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 SEN00703-03
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 SEN00704-01
Cooling system........................................................................................................................ 2
Engine mount and transmission mount ................................................................................... 5
Joint......................................................................................................................................... 6
Cooling fan pump..................................................................................................................... 8
Cooling fan motor .................................................................................................................... 15
Power train, Part 1 SEN00705-03
Power train............................................................................................................................... 2
Power train system diagram .................................................................................................... 3
Drive shaft................................................................................................................................ 5
Power train piping diagram......................................................................................................8
Torque converter...................................................................................................................... 10
Torque converter regulator valve............................................................................................. 28
Transmission............................................................................................................................ 30
Transfer.................................................................................................................................... 50
Transmission control valve ......................................................................................................52
ECMV ...................................................................................................................................... 58
Main relief valve and torque converter relief valve .................................................................. 65
Lubrication relief valve............................................................................................................. 67
Power train, Part 2 SEN00864-02
Torque converter oil cooler ...................................................................................................... 2
Torque converter oil filter ......................................................................................................... 3
Center support......................................................................................................................... 6
Axle.......................................................................................................................................... 8
Differential................................................................................................................................ 10
Limited slip differential ............................................................................................................. 19
Final drive................................................................................................................................ 24
Steering system SEN00706-03
Steering piping diagram........................................................................................................... 2
Steering column....................................................................................................................... 3
Steering control valve .............................................................................................................. 4
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00 Index and foreword SEN00701-19
WA500-6 5
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............................................................................................................... 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
Axle mount............................................................................................................................... 2
Center hinge pin...................................................................................................................... 7
Hydraulic system, Part 1 SEN00709-02
Hydraulic piping diagram......................................................................................................... 2
Work equipment control lever linkage ..................................................................................... 4
Hydraulic tank.......................................................................................................................... 5
Steering pump ......................................................................................................................... 7
Work equipment hydraulic pump............................................................................................. 18
Hydraulic system, Part 2 SEN00875-01
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 SEN00710-02
Work equipment linkage..........................................................................................................2
Bucket...................................................................................................................................... 6
Bucket positioner and boom kick-out....................................................................................... 8
Work equipment lubrication..................................................................................................... 9
Work equipment cylinder.........................................................................................................11
Cab and its attachments SEN00711-01
ROPS cab................................................................................................................................ 2
Air conditioner.......................................................................................................................... 4
Electrical system, Part 1 SEN00712-04
Machine monitor system..........................................................................................................2
Machine monitor...................................................................................................................... 10
Electrical system, Part 2 SEN00713-02
Work equipment control system .............................................................................................. 2
Transmission controller system............................................................................................... 36
Electrical system, Part 3 SEN00874-02
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
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SEN00701-19 00 Index and foreword
6WA500-6
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................................................................................... 2
Standard service value table for chassis ................................................................................. 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN00725-07
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Measuring engine speed ......................................................................................................... 7
Measuring exhaust gas color................................................................................................... 9
Measuring exhaust temperature.............................................................................................. 11
Adjusting valve clearance........................................................................................................ 13
Testing compression pressure................................................................................................. 14
Measuring blow-by pressure.................................................................................................... 16
Measuring engine oil pressure................................................................................................. 17
Measuring intake air (boost) pressure..................................................................................... 18
Handling fuel system equipment.............................................................................................. 20
Releasing residual pressure in fuel system............................................................................. 20
Testing fuel pressure................................................................................................................ 21
Testing return rate and leakage............................................................................................... 22
Bleeding air from fuel circuit .................................................................................................... 25
Testing leakage in fuel system................................................................................................. 27
Handling reduced cylinder mode operation............................................................................. 28
Handling no injection cranking operation................................................................................. 28
Handling controller voltage circuit............................................................................................ 29
Testing and adjusting alternator belt tension ........................................................................... 30
Testing and adjusting air conditioner compressor belt tension ................................................ 31
Adjusting transmission speed sensor...................................................................................... 32
Measuring directional lever (Steering wheel specification)...................................................... 34
Testing and adjusting power train oil pressure......................................................................... 35
Flushing procedure for torque converter and transmission hydraulic circuit............................ 48
Method of moving machine when transmission valve is broken.............................................. 51
Testing and adjusting, Part 2 SEN00726-06
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 of accumulator nitrogen gas pressure and procedure for charging accumulator
with nitrogen gas .............................................................................................................. 18
Testing and adjusting accumulator charge pressure ............................................................... 23
Testing wheel brake oil pressure ............................................................................................. 25
Measuring wear of wheel brake disc ....................................................................................... 27
Bleeding air from brake circuit.................................................................................................28
Releasing residual pressure in brake accumulator circuit ....................................................... 30
Testing parking brake performance ......................................................................................... 31
Measuring parking brake oil pressure...................................................................................... 32
Testing wear of parking brake disc .......................................................................................... 35
Method of releasing parking brake manually........................................................................... 36
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00 Index and foreword SEN00701-19
WA500-6 7
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) ............................................................................................................48
Testing and adjusting bucket positioner................................................................................... 49
Testing and adjusting lift arm position detecting lever ............................................................. 51
Checking proximity switch operation indication lamp .............................................................. 52
Procedure for testing diodes....................................................................................................53
Preparations for work on troubleshooting of electrical system ................................................ 54
Testing and adjusting, Part 3 SEN00727-05
How to start KOMTRAX terminal operations (if equipped)...................................................... 2
Indicator lamps of KOMTRAX terminal (if equipped)............................................................... 7
Machine monitor-based adjustment at replacement, disassembly and assembly,
and additional installation for each sensor and controller ................................................ 10
Special functions of machine monitor (EMMS)........................................................................ 12
Testing and adjusting, Part 4 SEN00728-07
Special functions of machine monitor (EMMS)........................................................................ 2
Pm clinic inspection table ........................................................................................................ 40
40 Troubleshooting
General information on troubleshooting SEN00729-02
Points to remember when performing troubleshooting.............................................................. 2
How to proceed in troubleshooting............................................................................................ 4
Testing before troubleshooting ..................................................................................................6
Classification and procedures of troubleshooting...................................................................... 7
Information in troubleshooting table .......................................................................................... 11
Troubleshooting method for disconnecting wiring harness of pressure sensor system............ 13
Connection table for connector pin numbers............................................................................. 15
T- branch box and T- branch adapter table............................................................................... 51
Troubleshooting by failure code (Display of code), Part 1 SEN00730-01
Failure codes list........................................................................................................................ 3
Before carrying out troubleshooting for electrical system.......................................................... 14
Information contained in troubleshooting table.......................................................................... 16
Failure code [1500L0] (TORQFLOW transmission : Double meshing)..................................... 18
Failure code [15B0NX] (Transmission filter: Clogged) .............................................................. 20
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) ..... 22
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) .... 24
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)..... 26
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF).... 28
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)... 30
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).. 32
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).. 34
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF). 36
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).. 38
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF). 40
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).. 42
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) . 44
Failure code [2F00MA] (Parking brake: Malfunction)................................................................ 46
Failure code [2G42ZG] (Front accumulator: Low oil pressure)................................................. 48
Troubleshooting by failure code (Display of code), Part 2 SEN00731-03
Failure code [2G43ZG] Rear accumulator: Low oil pressure.................................................... 4
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree........................................ 6
Failure code [AA1ANX] Air cleaner: Clogging........................................................................... 9
Failure code [AB00L6] Alternator: Signal disagrees with operating state of engine................. 11
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SEN00701-19 00 Index and foreword
8WA500-6
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...................................................... 22
Failure code [B@CENS] Torque converter oil: Overheating ..................................................... 23
Failure code [B@GAZK] Battery electrolyte: Low level............................................................. 24
Failure code [B@HANS] Hydraulic oil: Overheating.................................................................. 25
Failure code [CA111] Abnormality in engine controller.............................................................. 26
Failure code [CA115] Engine Ne or Bkup speed sensor error................................................... 29
Failure code [CA122] Charge (boost) pressure sensor high error............................................. 30
Failure code [CA123] Charge (boost) pressure sensor low error.............................................. 32
Failure code [CA131] Throttle sensor high error........................................................................ 34
Failure code [CA132] Throttle sensor low error......................................................................... 37
Failure code [CA135] Engine oil pressure sensor high error..................................................... 40
Failure code [CA141] Engine oil pressure sensor low error...................................................... 42
Failure code [CA144] Coolant temperature sensor high error................................................... 44
Failure code [CA145] Coolant temperature sensor low error.................................................... 46
Failure code [CA153] Charge (boost) temperature sensor high error....................................... 48
Failure code [CA154] Charge (boost) temperature sensor low error ........................................ 50
Failure code [CA187] Sensor power supply 2 low error............................................................ 52
Failure code [CA221] Atmospheric pressure sensor high error................................................. 56
Failure code [CA222] Atmospheric pressure sensor low error.................................................. 58
Failure code [CA227] Sensor power supply 2 high error........................................................... 60
Troubleshooting by failure code (Display of code), Part 3 SEN00732-04
Failure code [CA234] Engine overspeed................................................................................. 3
Failure code [CA238] Ne speed sensor power supply error.................................................... 4
Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 6
Failure code [CA265] Fuel Temp Sensor Low Error................................................................ 8
Failure code [CA271] PCV1 Short circuit................................................................................. 10
Failure code [CA272] PCV1 Disconnection............................................................................. 11
Failure code [CA273] PCV2 Short circuit................................................................................. 12
Failure code [CA274] PCV2 Disconnection............................................................................. 13
Failure code [CA322] Injector #1 open/short error................................................................... 14
Failure code [CA323] Injector #5 open/short error................................................................... 16
Failure code [CA324] Injector #3 open/short error................................................................... 18
Failure code [CA325] Injector #6 open/short error................................................................... 20
Failure code [CA331] Injector #2 open/short error................................................................... 22
Failure code [CA332] Injector #4 open/short error................................................................... 24
Failure code [CA342] Calibration code inconsistency ............................................................. 26
Failure code [CA351] Injectors drive circuit error..................................................................... 27
Failure code [CA352] Sens Supply 1 Volt Low Error............................................................... 28
Failure code [CA386] Sensor power supply 1 high error......................................................... 30
Failure code [CA431] Idle validation switch error .................................................................... 31
Failure code [CA432] Idle validation action error..................................................................... 34
Failure code [CA441] Battery voltage low error....................................................................... 37
Failure code [CA442] Battery voltage high error...................................................................... 38
Failure code [CA449] Common rail pressure high error 2....................................................... 39
Failure code [CA451] Rail Press Sensor High Error................................................................ 40
Failure code [CA452] Rail Press Sensor Low Error................................................................. 42
Failure code [CA553] Common rail pressure high error 1....................................................... 44
Failure code [CA554] Common rail pressure sensor in range error ........................................ 45
Failure code [CA559] Supply pump pressure very low error 1 ................................................ 46
Failure code [CA689] Engine Ne speed sensor error.............................................................. 50
Failure code [CA731] Engine Bkup speed sensor phase error................................................ 52
Failure code [CA757] All continuous data lost error ................................................................ 53
Failure code [CA778] Engine Bkup speed sensor error .......................................................... 54
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