Komatsu Wheel Loader WA500-R Series Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA500-6R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Wheel Loader WA500-6R workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 2,208 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

PEN00501-00 - Wheel Loader WA500-6R Operation & Maintenance Manual.pdf
SEN02876-09 - Wheel Loader WA500-6R Shop Manual.pdf

MAIN SECTIONS
COVER...1
00 Index and foreword...0
  Index...3
    Composition of shop manual...4
    Table of contents...6
  Foreword and general information...19
    Safety notice...20
    How to read the shop manual...25
    Explanation of terms for maintenance standard...27
    Handling of electric equipment and hydraulic component...29
    Handling of connectors newly used for engines...38
    How to read electric wire code...41
    Precautions when carrying out operation...44
    Method of disassembling and connecting push-pull type coupler...47
    Standard tightening torque table...50
    Conversion table...54
01 Specification...0
  Specification and technical data...61
    Specification dimension drawing...62
    Specifications...63
    Weight table...66
    Table of fuel, coolant and lubricants...68
10 Structure, function and maintenance standard...0
  Engine and cooling system...71
    Cooling system...72
    Engine mount and transmission mount...75
  Power train, Part 1...77
    Power train...78
    Power train system diagram...79
    Joint...81
    Drive shaft...82
    Power train piping diagram...83
    Torque converter...84
    Torque converter regulator valve...102
    Transmission...104
    Transfer...124
    Transmission control valve...126
    ECMV...130
    Main relief valve and torque converter relief valve...137
    Lubrication relief valve...139
  Power train, Part 2...141
    Torque converter oil cooler...142
    Torque converter oil filter...143
    Center support...146
    Axle...148
    Differential...150
    Limited slip differential...159
    Final drive...164
  Steering system...169
    Steering piping diagram...170
    Steering column...171
    Steering control valve...172
    Steering valve...183
    Stop valve...187
    Joystick steering lever linkage (if equipped)...188
    Steering cylinder...189
    Emergency steering piping diagram (if equipped)...192
    Diverter valve...193
  Brake system...199
    Brake piping diagram...200
    Brake valve...202
    Slack adjuster...207
    Accumulator charge valve...210
    PPC relief valve...214
    Accumulator (for brake)...216
    Brake...218
    Parking brake control...221
    Parking brake...222
    Parking brake solenoid valve...224
    Emergency parking brake release valve...226
  Undercarriage and frame...229
    Axle mount...230
    Center hinge pin...235
  Hydraulic system, Part 1...239
    Hydraulic piping diagram...240
    Work equipment control lever linkage...242
    Hydraulic tank...243
    Cooling fan motor...245
    Cooling fan pump...252
    Steering pump...259
    Work equipment hydraulic pump...270
  Hydraulic system, Part 2...291
    Control valve...292
    CLSS...306
    Each function and operation of each valve...311
    Accumulator (for PPC circuit)...322
    Work equipment electric lever...323
  Work equipment...327
    Work equipment linkage...328
    Bucket...332
    Bucket positioner and boom kick-out...334
    Work equipment lubrication...335
  Cab and its attachments...339
    ROPS cab...340
    Air conditioner...342
  Electrical system, Part 1...351
    Machine monitor system...352
    Machine monitor...360
  Electrical system, Part 2...415
    Work equipment control system...416
    Transmission controller system...450
  Electrical system, Part 3...483
    Electric transmission control...484
    Engine starting circuit...488
    Engine stopping circuit...490
    Preheating circuit...491
    Parking brake circuit...493
    Backup and stop lamp circuits...498
    Small lamp and head lamp circuits...500
    Working lamp circuit...501
    Horn circuit...502
    Wiper and window washer circuits...503
    Sensor...506
    KOMTRAX terminal system (if equipped)...524
20 Standard value table...0
  Standard service value table...527
    Standard service value table for engine...528
    Standard service value table for chassis...529
30 Testing and adjusting...0
  Testing and adjusting, Part 1...539
    Tools for testing, adjusting, and troubleshooting...541
    Measuring engine speed...548
    Measuring exhaust gas color...550
    Measuring exhaust temperature...552
    Adjusting valve clearance...554
    Testing compression pressure...555
    Measuring blow-by pressure...557
    Measuring engine oil pressure...558
    Measuring intake air (boost) pressure...559
    Handling fuel system equipment...561
    Releasing residual pressure in fuel system...561
    Testing fuel pressure...562
    Testing return rate and leakage...563
    Bleeding air from fuel circuit...566
    Testing leakage in fuel system...568
    Handling reduced cylinder mode operation...569
    Handling no injection cranking operation...569
    Handling controller voltage circuit...570
    Testing and adjusting alternator belt tension...571
    Testing and adjusting air conditioner compressor belt tension...572
    Adjusting transmission speed sensor...573
    Measuring directional lever (Steering wheel specification)...575
    Testing and adjusting power train oil pressure...576
    Flushing procedure for torque converter and transmission hydraulic circuit...589
    Method of moving machine when transmission valve is broken...592
  Testing and adjusting, Part 2...595
    Testing and adjusting steering stop valve...597
    Testing and adjusting steering wheel...599
    Testing steering oil pressure...601
    Bleeding air from steering cylinder circuit...604
    Testing hydraulic drive fan...605
    Bleeding air from hydraulic drive fan circuit...608
    Measuring brake pedal...610
    Measuring brake performance...611
    Testing and adjusting accumulator charge pressure...612
    Testing and adjusting accumulator charge pressure...617
    Testing wheel brake oil pressure...619
    Measuring wear of wheel brake disc...621
    Bleeding air from brake circuit...622
    Releasing residual pressure in brake accumulator circuit...624
    Testing parking brake performance...625
    Measuring parking brake oil pressure...626
    Testing wear of parking brake disc...629
    Method of releasing parking brake manually...630
    Measuring and adjusting work equipment control lever...631
    Testing and adjusting work equipment PPC oil pressure...632
    Measuring work equipment oil pressure...634
    Bleeding air from work equipment circuit...640
    Releasing residual pressure in work equipment circuit...641
    Method of moving machine when removing operator cab (when splittable cab is used)...642
    Testing and adjusting bucket positioner...643
    Testing and adjusting lift arm position detecting lever...645
    Checking proximity switch operation indication lamp...646
    Procedure for testing diodes...647
    Preparations for work on troubleshooting of electrical system...648
  Testing and adjusting, Part 3...653
    Starting KOMTRAX terminal operations...654
    Indicator lamps of KOMTRAX terminal...660
    Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller...663
    Special functions of machine monitor (EMMS)...665
  Testing and adjusting, Part 4...705
    Special functions of machine monitor (EMMS)...706
    Pm clinic inspection table...744
40 Troubleshooting...0
  Failure codes list and fuse locations...749
    Failure codes list...750
    Fuse locations...761
  General information on troubleshooting...765
    Points to remember when troubleshooting...766
    Sequence of events in troubleshooting...767
    Testing before troubleshooting...768
    Classification and procedures of troubleshooting...769
    Information contained in troubleshooting table...770
    Phenomena looking like troubles and troubleshooting Nos...772
    Connection table for connector pin numbers...774
    T- branch box and T- branch adapter table...810
  Troubleshooting by failure code (Display of code), Part 1...815
    Failure code [1500L0] (TORQFLOW transmission : Double meshing)...817
    Failure code [15B0NX] (Transmission filter: Clogged)...818
    Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...820
    Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...822
    Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...824
    Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...826
    Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...828
    Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...830
    Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...832
    Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...834
    Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...836
    Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...838
    Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...840
    Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...842
    Failure code [2F00MA] (Parking brake: Malfunction)...844
    Failure code [2G42ZG] (Front accumulator: Low oil pressure)...846
  Troubleshooting by failure code (Display of code), Part 2...849
    Failure code [2G43ZG] (Rear accumulator: Low oil pressure)...852
    Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)...854
    Failure code [AA1ANX] (Air cleaner: Clogging)...856
    Failure code [AB00L6] (Alternator: Signal does not match engine running or stopped state)...858
    Failure code [AB00MA] (Alternator: Malfunction)...860
    Failure code [B@BAZG] (Engine oil: Low oil pressure)...862
    Failure code [B@BAZK] (Engine oil: Low level)...864
    Failure code [B@BCNS] (Coolant: Overheating)...866
    Failure code [B@BCZK] (Coolant: Low level)...868
    Failure code [B@C7NS] (Brake oil: Overheating)...870
    Failure code [b@CENS] (Torque converter oil: Overheating)...872
    Failure code [B@CENS] (Torque converter oil: Overheating)...874
    Failure code [B@GAZK] (Battery electrolyte: Low level)...876
    Failure code [B@HANS] (Hydraulic oil: Overheating)...878
    Failure code [CA111] (Abnormality in engine controller)...880
    Failure code [CA115] (Engine Ne or Bkup speed sensor error)...883
    Failure code [CA122] (Charge pressure sensor high error)...884
    Failure code [CA123] (Charge pressure sensor low error)...886
    Failure code [CA131] (Throttle sensor high error)...887
    Failure code [CA132] (Throttle sensor low error)...889
    Failure code [CA135] (Engine oil pressure sensor high error)...890
    Failure code [CA141] (Engine oil pressure sensor low error)...892
    Failure code [CA144] (Coolant temperature sensor high error)...894
    Failure code [CA145] (Coolant temperature sensor low error)...896
    Failure code [CA153] (Charge temperature sensor high error)...898
    Failure code [CA154] (Charge temperature sensor low error)...900
    Failure code [CA187] (Sensor power supply 2 voltage low error)...900
    Failure code [CA221] (Atmospheric pressure sensor high error)...901
    Failure code [CA222] (Atmospheric pressure sensor low error)...903
    Failure code [CA227] (Sensor power supply 2 voltage high error)...904
  Troubleshooting by failure code (Display of code), Part 3...907
    Failure code [CA234] (Engine overspeed)...909
    Failure code [CA238] (Ne speed sensor power supply error)...910
    Failure code [CA263] (Fuel temperature sensor high error)...912
    Failure code [CA265] (Fuel temperature sensor low error)...914
    Failure code [CA271] (PCV1 Short circuit)...916
    Failure code [CA272] (PCV1 Disconnection)...918
    Failure code [CA273] (PCV2 Short circuit)...920
    Failure code [CA274] (PCV2 Disconnection)...922
    Failure code [CA322] (Injector #1 open/short error)...924
    Failure code [CA323] (Injector #5 open/short error)...926
    Failure code [CA324] (Injector #3 open/short error)...928
    Failure code [CA325] (Injector #6 open/short error)...930
    Failure code [CA331] (Injector #2 open/short error)...932
    Failure code [CA332] (Injector #4 open/short error)...934
    Failure code [CA342] (Engine controller data inconsistency)...936
    Failure code [CA351] (Injector drive circuit error)...937
    Failure code [CA352] (Sensor power supply 1 low error)...940
    Failure code [CA386] (Sensor power supply 1 high error)...942
    Failure code [CA431] (Idle validation switch error)...944
    Failure code [CA432] (Idle validation action error)...946
    Failure code [CA441] (Battery voltage low error)...946
    Failure code [CA442] (Battery voltage high error)...947
    Failure code [CA449] Common rail pressure high error 2...947
    Failure code [CA451] (Common rail pressure sensor high error)...948
    Failure code [CA452] (Common rail pressure sensor low error)...950
    Failure code [CA553] (Common rail pressure high error 1)...951
    Failure code [CA554] (Common rail pressure sensor in-range error)...952
    Failure code [CA559] (Supply pump pressure very low error 1)...953
    Failure code [CA689] (Engine Ne speed sensor error)...958
    Failure code [CA731] (Engine Bkup speed sensor phase error)...960
    Failure code [CA757] (All continuous data lost error)...960
    Failure code [CA778] (Engine Bkup speed sensor error)...962
    Failure code [CA1633] (KOMNET datalink timeout error)...964
  Troubleshooting by failure code (Display of code), Part 4...967
    Failure code [CA2185] (Throttle sensor supply voltage high error)...970
    Failure code [CA2186] (Throttle sensor power supply low error)...972
    Failure code [CA2249] (Supply pump pressure very low error 2)...972
    Failure code [CA2555] (Intake heater relay disconnection error)...973
    Failure code [CA2556] (Intake heater relay short circuit error)...974
    Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)...976
    Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...978
    Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...980
    Failure code [D192KA] (ECSS solenoid: Disconnection)...982
    Failure code [D192KB] (ECSS solenoid: Short circuit)...983
    Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...984
    Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)...986
    Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)...988
    Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)...990
    Failure code [D5ZHKA] (Terminal C signal: Disconnection)...992
    Failure code [D5ZHKB] (Terminal C signal: Short circuit)...994
    Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)...996
    Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...998
    Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...1000
    Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...1002
    Failure code [DAF5KP] (Machine monitor: Low output voltage)...1004
    Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)...1006
    Failure code [DAQ0KK] (Transmission controller: Low source voltage)...1008
    Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...1010
    Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)...1012
    Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...1014
  Troubleshooting by failure code (Display of code), Part 5...1017
    Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)...1020
    Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...1022
    Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...1024
    Failure code [DB90KK] Work equipment controller: Low source voltage (input)...1026
    Failure code [DB90KT] (Work equipment controller: Abnormality in controller)...1028
    Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...1030
    Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range)...1032
    Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals)...1034
    Failure code [DB9RKR] (CAN communication with work equipment controller: Defective communication (Abnormality in target component system)...1036
    Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...1038
    Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation)...1040
    Failure code [DD15LD] (? switch (Panel switch 1): Switch is kept pressed for long time)...1042
    Failure code [DD16LD] (? switch (Panel switch 2): Switch is kept pressed for long time)...1044
    Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)...1046
    Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)...1048
    Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time)...1050
    Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time)...1052
    Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time)...1054
    Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept pressed for long time)...1056
    Failure code [DD1GLD] (Load meter mode selector switch (+/-): Switch is kept pressed for long time)...1058
    Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...1060
    Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree)...1062
    Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit)...1064
    Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit)...1066
    Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...1068
  Troubleshooting by failure code (Display of code), Part 6...1071
    Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)...1074
    Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)...1076
    Failure code [DDK3KA] (Right FNR switch: Disconnection)...1078
    Failure code [DDK3KB] (Right FNR switch: Short circuit)...1080
    Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)...1082
    Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)...1084
    Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)...1086
    Failure code [DDK6KA] (FNR lever switch: Disconnection)...1088
    Failure code [DDK6KB] (FNR lever switch: Short circuit)...1092
    Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...1094
    Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...1096
    Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...1098
    Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...1100
    Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...1102
    Failure code [DF10KA] (Transmission shift lever switch: Disconnection)...1104
    Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...1108
    Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)...1110
    Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...1112
    Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...1114
    Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)...1116
    Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...1118
    Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...1120
    Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)...1122
  Troubleshooting by failure code (Display of code), Part 7...1125
    Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)...1128
    Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...1130
    Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...1132
    Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range)...1134
    Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine)...1136
    Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...1138
    Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...1142
    Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)...1145
    Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)...1148
    Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)...1151
    Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)...1154
    Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)...1157
    Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...1160
    Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)...1163
    Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...1166
    Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection)...1169
    Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)...1171
    Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)...1173
    Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)...1176
  Troubleshooting by failure code (Display of code), Part 8...1179
    Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)...1182
    Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)...1184
    Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...1186
    Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...1188
    Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)...1190
    Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)...1192
    Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)...1196
    Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)...1198
    Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)...1200
    Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)...1202
    Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)...1204
    Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)...1206
    Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)...1208
    Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range)...1210
    Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...1212
    Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)...1214
    Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)...1216
    Failure code [DV00KB] (Alarm buzzer: Short circuit)...1218
    Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...1220
    Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...1221
    Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)...1222
    Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...1224
    Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...1225
    Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)...1226
    Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...1228
    Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...1230
    Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...1232
  Troubleshooting by failure code (Display of code), Part 9...1235
    Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...1237
    Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...1238
    Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...1240
    Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...1242
    Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...1244
    Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...1246
    Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)...1248
    Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)...1248
    Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)...1249
    Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)...1250
    Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...1252
    Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...1254
    Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)...1256
    Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)...1258
    Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)...1260
    Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)...1262
    Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)...1264
    Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)...1266
    Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)...1268
    Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)...1270
    Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Short circuit with power supply line)...1272
    Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)...1274
    Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)...1275
    Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...1276
    Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)...1277
    Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)...1278
    Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...1279
    Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...1280
    Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...1282
    Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...1284
    Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...1286
  Troubleshooting by failure code (Display of code), Part 10...1289
    Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...1292
    Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...1294
    Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...1296
    Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...1298
    Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...1300
    Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...1302
    Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...1304
    Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...1306
    Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...1308
    Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...1310
    Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...1312
    Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...1314
    Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...1316
    Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...1318
    Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...1320
    Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...1322
    Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)...1324
    Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)...1325
    Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line)...1326
    Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)...1327
    Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)...1328
    Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line)...1329
    Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)...1330
    Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)...1332
    Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...1334
    Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...1336
    Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...1338
    Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)...1340
  Troubleshooting of electrical system (E-mode)...1343
    Fuse locations...1345
    Information in troubleshooting table...1348
    E-1 Engine does not start...1349
    E-2 Wiper does not operate...1354
    E-3 Windshield washer does not operate...1358
    E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...1361
    E-5 Working lamp does not light up or go off...1369
    E-6 Turn signal lamp and hazard lamp do not light up or go off...1374
    E-7 Brake lamp does not light or it keeps lighting up...1380
    E-8 Backup lamp does not light or it keeps lighting up...1382
    E-9 Backup buzzer does not sound or it keeps sounding...1384
    E-10 Horn does not sound or it keeps sounding...1386
    E-11 Alarm buzzer does not sound or it keeps sounding...1389
    E-12 Air conditioner does not operate or stop...1391
    E-13 KOMTRAX system does not work properly...1394
    E-14 Electric priming pump does not operate or does not stop automatically...1396
  Troubleshooting of hydraulic and mechanical system (H-mode)...1399
    Method of using troubleshooting chart...1401
    Table of failure modes and causes...1404
    H-1 Machine does not start...1408
    H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...1410
    H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)]...1411
    H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted...1412
    H-5 Shocks are large at the times of starting and shifting gear...1414
    H-6 Time lag is large at the times of starting and shifting gear...1416
    H-7 Torque converter oil temperature is high...1418
    H-8 Steering does not turn...1419
    H-9 Steering does not turn [Machine with joystick steering (if equipped)]...1420
    H-10 Steering response is low...1421
    H-11 Turning response of steering is poor [machine with joystick steering (if equipped)]...1422
    H-12 Steering is heavy...1423
    H-13 When machine turns, it shakes or makes large shocks...1424
    H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]...1425
    H-15 Wheel brake does not work or does not work well...1426
    H-16 Wheel brake is not released or it drags...1427
    H-17 Parking brake does not work or does not work well...1428
    H-18 Parking brake is not released or it drags (including emergency release system)...1429
    H-19 Lift arm does not rise...1430
    H-20 Lift arm speed is low or rising force of lift arm is insufficient...1431
    H-21 When rising, lift arm comes to move slowly at specific height...1432
    H-22 Lift arm cylinder cannot hold down bucket (Bucket floats)...1432
    H-23 Hydraulic drifts of lift arm occur often...1432
    H-24 Lift arm wobbles during operation...1432
    H-25 Bucket does not tilt back...1433
    H-26 Bucket speed is low or tilting back force is insufficient...1434
    H-27 Bucket comes to operate slowly in the midst of tilting-back...1435
    H-28 Bucket cylinder cannot hold down the bucket...1435
    H-29 Hydraulic drifts of bucket occur often...1435
    H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to ?HOLD?)...1435
    H-31 During operation of machine, engine speed lowers remarkably or engine stalls...1436
    H-32 Large shocks are made when work equipment starts and stops...1436
    H-33 When work equipment circuit is relieved singly, other work equipment moves...1436
    H-34 ECSS does not operate, and pitching and bouncing occur...1437
  Troubleshooting of engine (S-mode)...1439
    Method of using troubleshooting chart...1441
    S-1 Engine does not start easily...1444
    S-2 Engine does not start...1445
    S-3 Engine does not pick up smoothly...1448
    S-4 Engine stops during operation...1449
    S-5 Engine does not rotate smoothly (Engine hunts.)...1450
    S-6 Engine lacks output (or lacks power)...1451
    S-7 Exhaust smoke is black (Incomplete combustion)...1452
    S-8 Oil is consumed much (or exhaust gas color is blue)...1453
    S-9 Engine oil becomes contaminated quickly...1454
    S-10 Fuel consumption is excessive...1455
    S-11 Coolant contains oil (blows back or reduces)...1456
    S-12 Oil pressure drops...1457
    S-13 Oil level rises (Water, fuel in oil)...1458
    S-14 Coolant temperature rises too high (Overheating)...1459
    S-15 Abnormal noise is made...1460
    S-16 Vibration is excessive...1461
    S-17 Air cannot be bled from fuel circuit...1462
50 Disassembly and assembly...0
  General information on disassembly and assembly...1465
    How to read this manual...1466
    Coating materials list...1468
    Special tool list...1471
    Sketches of special tools...1475
  Engine and cooling system (SAA6D140E-5)...1483
    Removal and installation of engine assembly...1484
    Removal and installation of radiator assembly...1489
    Removal and installation of air aftercooler...1491
    Removal and installation of cooling fan and fan motor assembly...1492
    Removal and installation of radiator guard and cooling fan motor assembly...1494
    Removal and installation of fuel tank assembly...1497
    Removal and installation of hood...1499
  Engine (SAA6D140E-5)...1503
    Removal and installation of fuel supply pump assembly...1504
    Removal and installation of cylinder head assembly...1508
    Removal and installation of fuel injector assembly...1519
    Removal and installation of engine front seal...1522
    Removal and installation of engine rear seal...1526
  Power train, Part 1...1533
    Removal and installation of torque converter and transmission assembly...1534
    Disconnection and connection of power train unit...1540
    Disassembly and assembly of input transfer assembly...1544
    Disassembly and assembly of torque converter assembly (Lockup specification)...1551
    Disassembly and assembly of torque converter assembly (Lockup-less specification)...1564
  Power train, Part 2...1577
    Disassembly and assembly of transmission assembly...1578
    Disassembly and assembly of transfer and parking brake assembly...1608
    Removal and installation of front axle assembly...1624
    Removal and installation of rear axle assembly...1626
  Power train, Part 3...1629
    Removal and installation of front differential assembly...1630
    Disassembly and assembly of differential assembly (LSD specification)...1632
    Disassembly and assembly of differential assembly (LSD-less specification)...1646
    Disassembly and assembly of final drive assembly (Front and rear)...1657
  Brake system...1665
    Removal and installation of brake assembly (Front and rear)...1666
    Disassembly and assembly of brake assembly (Front and rear)...1668
    Disassembly and assembly of slack adjuster assembly...1674
    Disassembly and assembly of brake accumulator charge valve assembly...1675
  Undercarriage and frame...1677
    Removal and installation of center hinge pin...1678
    Removal and installation of large counterweight assembly...1685
    Removal and installation of small counterweight assembly...1686
  Hydraulic system...1689
    Removal and installation of hydraulic tank assembly...1690
    Removal and installation of cooling pump assembly...1693
    Removal and installation of fan pump assembly...1694
    Removal and installation of work equipment pump assembly...1695
    Removal and installation of steering, torque converter charge and EPC pump assembly...1697
    Removal and installation of work equipment valve assembly...1698
    Disassembly and assembly of work equipment control valve assembly...1701
    Disassembly and assembly of steering cylinder assembly...1704
    Disassembly and assembly of lift arm and bucket cylinder assembly...1708
    Removal and installation of steering valve assembly...1714
  Work equipment...1717
    Removal and installation of work equipment assembly...1718
  Cab and its attachments...1723
    Removal and installation of operator's cab assembly (Separate cab and floor specification)...1724
    Removal and installation of operator's cab and floor frame assembly (Cab-floor unit specification)...1729
    Removal and installation of operator's cab glass (Stuck glass)...1733
    Disassembly and assembly of operator's seat assembly...1742
  Electrical system...1777
    Removal and installation of engine controller assembly...1778
    Removal and installation of transmission controller assembly...1779
    Removal and installation of work equipment controller assembly...1780
    Removal and installation of air conditioner unit assembly...1781
90 Diagrams and drawings...0
  Hydraulic diagrams and drawings...1787
    Power train hydraulic circuit diagram...1789
    Brake hydraulic circuit diagram...1791
    Work equipment hydraulic circuit diagram...1793
  Electrical diagrams and drawings...1796
    Air conditioner electrical circuit diagram...1798
    Electrical circuit diagram (1/7)...1799
    Electrical circuit diagram (2/7)...1800
    Electrical circuit diagram (3/7)...1801
    Electrical circuit diagram (4/7)...1802
    Electrical circuit diagram (5/7)...1803
    Electrical circuit diagram (6/7)...1804
    Electrical circuit diagram (7/7)...1805
    Connector arrangement diagram...1806

COVER...1
FOREWORD...2
  BEFORE READING THIS MANUAL...3
  SAFETY INFORMATION...4
  INTRODUCTION...5
    FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...5
    VISIBILITY FROM OPERATOR'S SEAT...6
  NECESSARY INFORMATION...7
    PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...7
    POSITION OF SERVICE METER...8
    TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...8
  CONTENTS...9
SAFETY...12
  SAFETY...13
  SAFETY LABELS...16
    LOCATION OF SAFETY LABELS...17
    SAFETY LABELS...18
  GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...25
    PRECAUTIONS BEFORE STARTING OPERATION...25
    PREPARATIONS FOR SAFE OPERATION...25
    FIRE PREVENTION...27
    PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...28
    DO NOT GET CAUGHT IN ARTICULATING PORTION...31
    PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...31
    UNAUTHORIZED MODIFICATION...31
    PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...31
    PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...32
  PRECAUTIONS FOR OPERATION...33
    PRECAUTIONS FOR JOBSITE...33
    STARTING ENGINE...35
    OPERATION...38
    TRANSPORTATION...44
    TOWING...45
  PRECAUTIONS FOR MAINTENANCE...46
    PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...46
    PRECAUTIONS FOR INSPECTION AND MAINTENANCE...51
    TIRES...56
OPERATION...58
  GENERAL VIEW...59
    GENERAL VIEW OF MACHINE...59
    GENERAL VIEW OF CONTROLS AND GAUGES...60
  EXPLANATION OF COMPONENTS...66
    MACHINE MONITOR...66
    SWITCHES...107
    CONTROL LEVERS, PEDALS...127
    STEERING TILT LOCK LEVER...134
    CAP WITH LOCK...135
    FRAME LOCK BAR...137
    TOWING PIN...138
    BACKUP ALARM...138
    OPENING, CLOSING CAB DOORS, WINDOWS...139
    HANDLING CAB WIPER...143
    DUST INDICATOR...143
    FUSE...144
    SLOW BLOW FUSE...146
    POWER OUTLET...146
    CAR RADIO...147
    AIR CONDITIONER...153
    LOCATION OF FIRE EXTINGUISHER...157
  OPERATION...158
    CHECK BEFORE STARTING ENGINE, ADJUST...158
    STARTING ENGINE...178
    OPERATIONS AND CHECKS AFTER STARTING ENGINE...180
    STOPPING ENGINE...182
    CHECK AFTER STOPPING ENGINE...182
    MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...183
    TURNING...193
    OPERATION OF WORK EQUIPMENT...195
    SEMI AUTO DIGGING OPERATIONS...197
    REMOTE POSITIONER...198
    WORK POSSIBLE USING WHEEL LOADER...200
    PRECAUTIONS FOR OPERATION...220
    REMOVAL AND INSTALLATION OF THE BUCKET...223
    PARKING MACHINE...226
    CHECKS AFTER COMPLETION OF OPERATION...227
    LOCKING...228
    HANDLING THE TIRES...229
  TRANSPORTATION...232
    TRANSPORTATION PROCEDURE...232
    LOADING, UNLOADING WORK WITH TRAILERS...232
    METHOD OF LIFTING MACHINE...236
  COLD WEATHER OPERATION...238
    PRECAUTIONS FOR LOW TEMPERATURE...238
    PRECAUTIONS AFTER COMPLETION OF WORK...239
    AFTER COLD WEATHER...239
    WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...240
  LONG-TERM STORAGE...241
    BEFORE STORAGE...241
    DURING STORAGE...241
    AFTER STORAGE...241
  TROUBLESHOOTING...242
    WHEN MACHINE RUNS OUT OF FUEL...242
    METHOD OF TOWING MACHINE...242
    IF BATTERY IS DISCHARGED...246
    METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...250
    OTHER TROUBLE...251
MAINTENANCE...256
  GUIDES TO MAINTENANCE...257
  OUTLINES OF SERVICE...259
    HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...259
    OUTLINE OF ELECTRIC SYSTEM...262
  WEAR PARTS...263
    WEAR PARTS LIST...263
  RECOMMENDED FUEL, COOLANT, AND LUBRICANT...265
    USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...266
    RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...268
  STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...269
    TORQUE LIST...269
  PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...270
    SAFETY CRITICAL PARTS...271
  MAINTENANCE SCHEDULE CHART...272
    MAINTENANCE SCHEDULE CHART...272
  SERVICE PROCEDURE...274
    INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...274
    INITIAL 250 HOURS SERVICE...274
    WHEN REQUIRED...275
    CHECK BEFORE STARTING...305
    EVERY 100 HOURS SERVICE...306
    EVERY 250 HOURS SERVICE...310
    EVERY 500 HOURS SERVICE...317
    EVERY 1000 HOURS SERVICE...322
    EVERY 2000 HOURS SERVICE...328
    EVERY 4000 HOURS SERVICE...335
    EVERY 8000 HOURS SERVICE...339
SPECIFICATIONS...340
  SPECIFICATIONS...341
ATTACHMENTS, OPTIONS...344
  HANDLING LOAD METER...345
    OUTLINE OF LOAD METER...345
    PRINCIPLE OF LOAD METER MEASUREMENT...347
    POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...349
    USING LOAD METER...351
  HANDLING JOYSTICK STEERING SYSTEM...382
    EXPLANATION OF COMPONENTS...382
    STRUCTURE AND FUNCTION OF JOYSTICK STEERING...386
    GETTING IN OR OUT OF OPERATOR'S CAB...387
    ADJUSTMENT OF JOYSTICK CONSOLE...388
    PRECAUTIONS FOR STEERING WITH JOYSTICK...392
    OPERATION METHOD OF JOYSTICK STEERING SYSTEM...392
  HANDLING MACHINES EQUIPPED WITH KOMTRAX...395
    BASIC PRECAUTIONS...395
INDEX...396