Professional Documents
Culture Documents
WA500-6
WA500-6 1
SEN00701-23 00 Index and foreword
01 Specification SEN00576-03
Specification and technical data SEN00703-03
40 Troubleshooting SEN00580-08
General information on troubleshooting SEN00729-02
Troubleshooting by failure code (Display of code), Part 1 SEN00730-01
2 WA500-6
00 Index and foreword SEN00701-23
80 Appendix SEN06709-00
Air conditioner SEN06710-00
WA500-6 3
SEN00701-23 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN00701-23
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
4 WA500-6
00 Index and foreword SEN00701-23
WA500-6 5
SEN00701-23 00 Index and foreword
Horn circuit............................................................................................................................... 20
Wiper and window washer circuits........................................................................................... 21
Sensor ..................................................................................................................................... 24
KOMTRAX system................................................................................................................... 42
6 WA500-6
00 Index and foreword SEN00701-23
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
WA500-6 7
SEN00701-23 00 Index and foreword
8 WA500-6
00 Index and foreword SEN00701-23
WA500-6 9
SEN00701-23 00 Index and foreword
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range
............................................................................................................................................ 24
Failure code [DB99KQ] Work equipment controller model selection: Disagreement of model selec-
tion signals........................................................................................................................ 26
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error
(Abnormality in target component system) ....................................................................... 27
Failure code [DB9RMA] Work equipment controller option setting: Malfunction ..................... 28
Failure code [DB9RMC] CAN communication with work equipment controller: Defective operation
............................................................................................................................................ 29
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ........ 30
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time ....... 32
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time ......... 34
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time ......... 36
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for
long time ........................................................................................................................... 38
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for
long time ........................................................................................................................... 40
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time ..... 42
Failure code [DD1FLD] Load meter mode selector switch (A/B):
Switch is kept pressed for long time .................................................................................. 44
Failure code [DD1GLD] Load meter mode selector switch (+/–):
Switch is kept pressed for long time .................................................................................. 46
Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time
............................................................................................................................................ 48
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree ......................... 50
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit............ 52
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit ....... 55
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree ........... 58
Troubleshooting by failure code (Display of code), Part 6 SEN00735-01
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time)................................................................................ 4
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) ............................... 6
Failure code [DDK3KA] (Right FNR switch: Disconnection).................................................... 8
Failure code [DDK3KB] (Right FNR switch: Short circuit) ....................................................... 10
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection).................................. 12
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) ..................................... 14
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) .. 16
Failure code [DDK6KA] (FNR lever switch: Disconnection) .................................................... 18
Failure code [DDK6KB] (FNR lever switch: Short circuit) ........................................................ 22
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) ..................... 24
Failure code [DDT4LD] (Transmission cut-off set switch:
Switch is kept pressed for long time)................................................................................ 26
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ................. 28
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) .......................... 30
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) ..... 32
Failure code [DF10KA] (Transmission shift lever switch: Disconnection)................................ 34
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) ................................... 38
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)...................... 40
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) ......................... 42
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)........... 44
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)......................... 46
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ........ 48
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 50
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) ............ 52
Troubleshooting by failure code (Display of code), Part 7 SEN00736-01
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) ................ 4
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 6
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) . 8
10 WA500-6
00 Index and foreword SEN00701-23
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) .................... 10
Failure code [DHT2L6] (Transmission filter clogging sensor:
Signal disagrees with operating and stopped states of engine) ....................................... 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)................. 14
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line) ................................................................................. 18
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) .. 21
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection).................. 24
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Short circuit with power supply line) ................................................................................. 27
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ................. 30
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):
Short circuit with power supply line) ................................................................................. 33
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) .. 36
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) .................. 39
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Short circuit with power supply line) ................................................................................. 42
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main):
Disconnection).................................................................................................................. 45
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main):
Short circuit with power supply line) ................................................................................. 47
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree) .................................................................................................. 49
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection).................................................................................................................. 52
Troubleshooting by failure code (Display of code), Part 8 SEN00737-01
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):
Short circuit with power supply line) ................................................................................. 4
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) .. 6
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line) ................................................................................. 8
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)... 10
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Short circuit with power supply line) ................................................................................. 12
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree) .................................................................................................. 14
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)................................................ 18
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) ............................... 20
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) ............... 22
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ............................................. 24
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) .................... 26
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)...... 28
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit) ...................... 30
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range).. 32
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).............................. 34
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)................. 36
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)................ 38
Failure code [DV00KB] (Alarm buzzer: Short circuit) ................................................................ 40
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)..................................... 42
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) ........................................ 43
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line).... 44
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) ................................... 46
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ....................................... 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)... 48
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection).......................................... 50
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) ............................................. 52
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)......... 54
WA500-6 11
SEN00701-23 00 Index and foreword
12 WA500-6
00 Index and foreword SEN00701-23
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ........................ 39
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) ........................... 40
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with
power supply line) ............................................................................................................ 41
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) ...................... 42
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit).......................... 44
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with
power supply line) ............................................................................................................ 46
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) ....................... 48
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) ........................... 50
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with
power supply line) ............................................................................................................ 52
Troubleshooting of electrical system (E-mode) SEN00740-03
Before carrying out troubleshooting of electrical system ......................................................... 3
Information in troubleshooting table ........................................................................................ 6
E-1 Engine does not start ........................................................................................................ 7
E-2 Wiper does not operate..................................................................................................... 12
E-3 Windshield washer does not operate................................................................................ 16
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off ............. 19
E-5 Working lamp does not light up or go off........................................................................... 27
E-6 Turn signal lamp and hazard lamp do not light up or go off .............................................. 32
E-7 Brake lamp does not light or it keeps lighting up .............................................................. 38
E-8 Backup lamp does not light or it keeps lighting up ............................................................ 40
E-9 Backup buzzer does not sound or it keeps sounding ....................................................... 42
E-10 Horn does not sound or it keeps sounding ..................................................................... 44
E-11 Alarm buzzer does not sound or it keeps sounding ........................................................ 47
E-12 Air conditioner does not operate or stop ......................................................................... 49
E-13 KOMTRAX system does not work properly .................................................................... 52
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00741-00
Method of using troubleshooting chart .................................................................................... 3
Table of failure modes and causes .......................................................................................... 6
H-1 Machine does not start ..................................................................................................... 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)]........................................................................ 12
H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)].. 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak,
and gear is not shifted ...................................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear ............................................... 16
H-6 Time lag is large at the times of starting and shifting gear................................................ 18
H-7 Torque converter oil temperature is high .......................................................................... 20
H-8 Steering does not turn....................................................................................................... 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] ............................... 22
H-10 Steering response is low................................................................................................. 23
H-11 Turning response of steering is poor [machine with joystick steering (if equipped)] ....... 24
H-12 Steering is heavy ............................................................................................................ 25
H-13 When machine turns, it shakes or makes large shocks.................................................. 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)]................................................................... 27
H-15 Wheel brake does not work or does not work well ......................................................... 28
H-16 Wheel brake is not released or it drags .......................................................................... 29
H-17 Parking brake does not work or does not work well ....................................................... 30
H-18 Parking brake is not released or it drags (including emergency release system)........... 31
H-19 Lift arm does not rise ...................................................................................................... 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient ........................................... 33
H-21 When rising, lift arm comes to move slowly at specific height ........................................ 34
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats).............................................. 34
H-23 Hydraulic drifts of lift arm occur often.............................................................................. 34
H-24 Lift arm wobbles during operation................................................................................... 34
WA500-6 13
SEN00701-23 00 Index and foreword
14 WA500-6
00 Index and foreword SEN00701-23
80 Appendix
Air conditioner SEN06710-00
Precautions for refrigerant ....................................................................................................... 3
Troubleshooting procedure...................................................................................................... 4
Circuit diagram and arrangement of connector pins................................................................ 6
System diagram....................................................................................................................... 11
Detail of air conditioner unit ..................................................................................................... 13
Parts and connectors layout .................................................................................................... 15
Testing with self-diagnosis function (indication on control panel) ............................................ 19
Testing temperature control ..................................................................................................... 22
Testing vent (mode) changeover ............................................................................................. 23
Testing Fresh/Recirc changeover ............................................................................................ 25
Testing inside air temp. sensor and outside air temp. sensor.................................................. 27
WA500-6 15
SEN00701-23 00 Index and foreword
16 WA500-6
00 Index and foreword SEN00701-23
WA500-6 17
SEN00701-23
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 10-20 (01)
18
SEN00702-05
WA500-6
WA500-6 1
SEN00702-05 Safety notice
Safety notice 1
2 WA500-6
Safety notice SEN00702-05
WA500-6 3
SEN00702-05 Safety notice
12) When assembling or installing parts, 7) Limit the hanging angle to 60°, as a rule.
always tighten them to the specified Do not sling a heavy load with ropes form-
torques. When installing protective parts ing a wide hanging angle from the hook.
such as guards, or parts which vibrate vio- When hoisting a load with 2 or more
lently or rotate at high speed, be particu- ropes, the force subjected to each rope
l ar l y c a r e f u l t o c h e c k t h a t t h e y a r e will increase with the hanging angle. The
installed correctly. table below shows the variation of allow-
13) When aligning 2 holes, never insert your able load in kN {kg} when hoisting is made
fingers or hand. Be careful not to get your with 2 ropes, each of which is allowed to
fingers caught in a hole. sling up to 9.8 kN {1,000 kg} vertically, at
14) When measuring hydraulic pressure, various hanging angles. When the 2 ropes
check that the measuring tools are cor- sling a load vertically, up to 19.6 kN {2,000
rectly assembled. kg} of total weight can be suspended.
15) Take care when removing or installing the This weight is reduced to 9.8 kN {1,000
tracks of track-type machines. When kg} when the 2 ropes make a hanging
removing the track, the track separates angle of 120°. If the 2 ropes sling a 19.6
suddenly, so never let anyone stand at kN {2,000 kg} load at a lifting angle of
either end of the track. 150°, each of them is subjected to a force
16) If the engine is operated for a long time in as large as 39.2 kN {4,000 kg}.
a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.
4 WA500-6
Safety notice SEN00702-05
WA500-6 5
SEN00702-05 Safety notice
6 WA500-6
How to read the shop manual SEN00702-05
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
WA500-6 7
SEN00702-05 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 WA500-6
Explanation of terms for maintenance standard SEN00702-05
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
WA500-6 9
SEN00702-05 Explanation of terms for maintenance standard
10 WA500-6
Handling of electric equipment and hydraulic component SEN00702-05
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
WA500-6 11
SEN00702-05 Handling of electric equipment and hydraulic component
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 WA500-6
Handling of electric equipment and hydraulic component SEN00702-05
WA500-6 13
SEN00702-05 Handling of electric equipment and hydraulic component
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 WA500-6
Handling of electric equipment and hydraulic component SEN00702-05
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
WA500-6 15
SEN00702-05 Handling of electric equipment and hydraulic component
16 WA500-6
Handling of electric equipment and hydraulic component SEN00702-05
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
WA500-6 17
SEN00702-05 Handling of electric equipment and hydraulic component
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 WA500-6
Handling of electric equipment and hydraulic component SEN00702-05
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WA500-6 19
SEN00702-05 Handling of connectors newly used for engines
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
20 WA500-6
Handling of connectors newly used for engines SEN00702-05
q 114 engine
q 107 engine
WA500-6 21
SEN00702-05 Handling of connectors newly used for engines
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 WA500-6
How to read electric wire code SEN00702-05
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
WA500-6 23
SEN00702-05 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 WA500-6
How to read electric wire code SEN00702-05
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
WA500-6 25
SEN00702-05 Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 WA500-6
Precautions when carrying out operation SEN00702-05
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
WA500-6 27
SEN00702-05 Precautions when carrying out operation
28 WA500-6
Method of disassembling and connecting push-pull type coupler SEN00702-05
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WA500-6 29
SEN00702-05 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 WA500-6
Method of disassembling and connecting push-pull type coupler SEN00702-05
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
WA500-6 31
SEN00702-05 Standard tightening torque table
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 WA500-6
Standard tightening torque table SEN00702-05
WA500-6 33
SEN00702-05 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 WA500-6
Standard tightening torque table SEN00702-05
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
WA500-6 35
SEN00702-05 Conversion table
Conversion table 1
Example: Method of using the conversion table to convert from millimeters to inches
36 WA500-6
Conversion table SEN00702-05
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WA500-6 37
SEN00702-05 Conversion table
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 WA500-6
Conversion table SEN00702-05
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA500-6 39
SEN00702-05 Conversion table
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 WA500-6
Conversion table SEN00702-05
WA500-6 41
SEN00702-05
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
42
SEN00703-03
WA500-6
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification dimension drawing .......................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ......................................................................................................................................... 6
Table of fuel, coolant and lubricants ..................................................................................................... 8
WA500-6 1
SEN00703-03 01 Specification
2 WA500-6
01 Specification SEN00703-03
Specifications 1
Tread mm 2,400
Minimum ground clearance mm 450
Max. hinge pin height of bucket mm 4,755
Dumping clearance mm 3,295 (with BOC)
Dumping reach mm 1,500 (with BOC)
Bucket tilt-forward angle deg. 46
Bucket tilt-back angle
deg. 50
(Operating posture)
Digging depth (Approx. 10°) mm 435
WA500-6 3
SEN00703-03 01 Specification
Performance
Nm/rpm
Max. torque 178.9/1,250 {182.4/1,250}
{kgm/rpm}
Fuel consumption rate, at rated g/kWh
216.2 {161}
speed {g/HPh}
Max. speed at no load rpm 2,150
Min. speed at no load rpm 675
Starting motor 24 V, 11 kW
Alternator 24 V, 75 A
Battery 12 V, 170 Ah x 2
Torque converter 3-element, 1-stage, 2-phase
Power train
4 WA500-6
01 Specification SEN00703-03
Work equipment hydraulic pump 321 (Variable displacement piston pump HPV190)
Steering pump l/min 120 (Variable displacement piston pump LPV90)
Cooling fan pump l/min 70 (Variable displacement piston pump LPV45)
Power train pump l/min 189 (Gear pump SAR (3) 112)
Hydraulic cooling pump l/min 94 (Gear pump SAL (3) 80)
l/min
Hydraulic system
Set pressure for work equipment MPa {kg/cm2} 3-spool type (with HI valve) 34.3 {350}
Set pressure for steering system MPa {kg/cm2} Spool type 24.5 {250}
Number of lift cylinders – Bore x Stroke mm Double-acting piston type 2 – 160 x 898
Number of bucket cylinders – Bore x Stroke mm Double-acting piston type 1 – 185 x 675
Number of steering cylinders – Bore x Stroke mm Double-acting piston type 2 – 100 x 486
Motor
Fan motor Fixed displacement piston type: LMF40
equipment
Work equipment
Work
WA500-6 5
SEN00703-03 01 Specification
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model name WA500-6
Serial number 55001 and up
Engine (dry weight) 1,700
Radiator (including air conditioner condenser) (dry weight) 326
Torque converter (including drive gear) (dry weight) 558
Transmission (dry weight) 1,106
Center drive shaft 45
Front drive shaft 45
Rear drive shaft 40
Center support 42
Front axle 2,250
Rear axle 2,084
Front differential 368
Rear differential 390
Planetary carrier assembly (1 piece) 69
Wheel hub (1 piece) 114
Axle pivot (front) 104
Axle pivot (rear) 126
Wheel (1 piece) 267
Tire (standard: 29.5-25-22PR L3) (1 piece) 532
Steering demand valve 24
Steering cylinder (1 piece) 53
Hydraulic tank (dry weight) 412
Work equipment hydraulic pump 106
Power train, EPC pump 22
Steering pump 39
Hydraulic cooling pump 13
Cooling fan pump 25
Torque converter oil cooler 70
Fan motor 13.4
Fan 29.1
6 WA500-6
01 Specification SEN00703-03
Unit: kg
Machine model name WA500-6
Serial number 55001 and up
Work equipment valve 110
Lift cylinder (1 piece) 282
Bucket cylinder 289
Engine hood 265
Radiator guard 355
Front frame 2,565
Rear frame 2,650
Bucket link (including bushing) 157
Bell crank (including bushing) 754
Lift arm (including bushing) 2,105
3
Bucket (5.2 m with teeth and segment edge) 2,960
Bucket (5.6 m3 with bolt-on cutting edge) 3,005
Counterweight 2,480
Fuel tank 220
Battery (1 piece) 56
Cab (including console box and dashboard) 987
Air conditioner unit 33
Operator seat 36
WA500-6 7
SEN00703-03 01 Specification
8 WA500-6
01 Specification SEN00703-03
WA500-6 9
SEN00703-03
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 07-17 (01)
10
SEN00704-01
WA500-6
WA500-6 1
SEN00704-01 10 Structure, function and maintenance standard
2 WA500-6
10 Structure, function and maintenance standard SEN00704-01
Specifications
Hydraulic oil Hydraulic oil Torque converter
Radiator Aftercooler
cooler (1) cooler (2) oil cooler
Aluminum tube in Straight fin
Core type PTO-OL PTO-OL PTO-LS
4-column 10-hole tube type
150 × 620 ×
Fin pitch (mm) 4.0/2P 100 × 385 × 17 100 × 558 × 17 6.0/2P
20-stage
Total heat dissipation
59.90 1.2187 1.829 21.57 3.254
surface (m2)
Cross sectional area
50.845 — — — —
of flow (cm2)
Pressure valve crack-
ing pressure 70 ± 15 — — — —
(kPa {kg/cm2})
Vacuum valve crack-
ing pressure 0–5 — — — —
(kPa {kg/cm2})
WA500-6 3
SEN00704-01 10 Structure, function and maintenance standard
4 WA500-6
10 Structure, function and maintenance standard SEN00704-01
Unit: mm
No Check item Criteria Remedy
Shim thickness: 0.5 mm, 1.0 mm
1 Shim thickness of mount (Shim thickness and number of shims used shall be the
same as that employed on the actual machine.)
Clearance between stopper and A clearance of 1.5 mm minimum shall be provided between
2
support the stopper and support.
Adjust
Shim thickness: 0.5 mm, 1.0 mm
3 Shim thickness of mount (Shim thickness and number of shims used shall be the
same as that employed on the actual machine.)
Clearance between stopper bolt A clearance of 1 to 1.5 mm minimum shall be provided
4
and bracket between the stopper and bracket.
WA500-6 5
SEN00704-01 10 Structure, function and maintenance standard
Joint 1
1. Ring gear
Unit: mm
No. Check item Criteria Remedy
Backlash of ring gear and torque converter
2 0.059 – 0.240 Replace
case gear
Outline
q The ring gear is installed to the flywheel of the
engine.
The internal teeth of the ring gear are meshed
with the external teeth of the torque converter
lockup clutch housing to transmit the power
from the engine to the torque converter.
6 WA500-6
10 Structure, function and maintenance standard SEN00704-01
WA500-6 7
SEN00704-01 10 Structure, function and maintenance standard
1. Servo valve
2. Air bleeder
8 WA500-6
10 Structure, function and maintenance standard SEN00704-01
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
WA500-6 9
SEN00704-01 10 Structure, function and maintenance standard
Function Structure
q The pump converts the engine rotation torque q Cylinder block (7) is supported to shaft (1) by
transmitted to its shaft to oil pressure and spline (11).
delivers pressurized oil corresponding to the q Shaft (1) is supported with front and rear bear-
load. ings (12).
q It is possible to change the delivery by chang- q The end of piston (6) has a spherical hollow
ing the swash plate angle. and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Shoe (5) is kept pressed against flat surface
(A) of rocker cam (4) and slid circularly.
q Rocker cam (4) slides around ball (13).
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
der block (7) is suctioned and discharged
through valve plate (8).
10 WA500-6
10 Structure, function and maintenance standard SEN00704-01
WA500-6 11
SEN00704-01 10 Structure, function and maintenance standard
12 WA500-6
10 Structure, function and maintenance standard SEN00704-01
Servo valve
WA500-6 13
SEN00704-01 10 Structure, function and maintenance standard
14 WA500-6
10 Structure, function and maintenance standard SEN00704-01
Specifications
Type : LMF40
Capacity : 40 cc/rev
Rated speed : 1,190 rpm
Rated flow : 47.6 l/min
Check valve cracking pressure: 44.1 kPa {0.45 kg/cm2}
WA500-6 15
SEN00704-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Free Installed
x Outside
13 Spool return spring length load length load If damaged or
diameter
deformed,
58.8 N 47.1 N replace spring
44.8 x 12.0 33.0 —
{6.0 kg} {4.8 kg}
1.96 N 1.57 N
14 Check valve spring 13.0 x 6.5 9.5 —
{0.2 kg} {0.16 kg}
16 WA500-6
10 Structure, function and maintenance standard SEN00704-01
Hydraulic motor
Function
q This motor is called a swash plate-type axial
piston motor. It converts the energy of the
pressurized oil sent from the pump into rotary
motion.
Principle of operation
q The oil sent from the pump flows through valve
plate (7) into cylinder block (5).
q This oil can flow on only one side of the (Y–Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (2 or 3 pieces) and gener-
ates force (F1).
q A single piston force F1 [F1 (kg) = P (kg/cm2) x
xD2/4 (cm2)]
q This force is applied to thrust plate (2).
q Since thrust plate (2) is fixed to a certain angle
(a) to output shaft (1), the force is divided into
components (F2) and (F3).
q Radial component (F3) generates torque [T =
F3 x ri] against the (Y – Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s(F3 x ri)] rotates
cylinder block (5) through piston (4).
q This cylinder block (5) is coupled to output
shaft (1) with the spline.
q Output shaft (1) rotates and torque is transmit-
ted.
WA500-6 17
SEN00704-01 10 Structure, function and maintenance standard
Suction valve
18 WA500-6
10 Structure, function and maintenance standard SEN00704-01
WA500-6 19
SEN00704-01 10 Structure, function and maintenance standard
Safety valve
Function
q When the engine is started, the pressure in
port (P) of the motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q Accordingly, abnormally high pressure is pre-
vented from being generated in port (P).
20 WA500-6
10 Structure, function and maintenance standard SEN00704-01
WA500-6 21
SEN00704-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
22
SEN00705-03
WA500-6
WA500-6 1
SEN00705-03 10 Structure, function and maintenance standard
Outline
q The power from engine (1) is transmitted to q Multi-disc type parking brake (10) is installed
torque converter (2) through the flywheel and on transmission. The power from the front side
ring gear. Torque converter (2) converts the output shaft is transmitted through center drive
transmitted toque according to the fluctuation shaft (11) and front drive shaft (13) to front dif-
of the load by using oil as a medium and then ferential (14). On the rear side, the power is
transmits the power to the input shaft of trans- transmitted to rear differential (19) from rear
mission (3). drive shaft (18).
The engine power is also transmitted through q The power being transmitted to front differen-
the pump drive gear (PTO) of torque converter tial (14) and rear differential (19) is then trans-
(2) to steering pump (4), torque converter mitted to the axle shaft.
charging pump (5), EPC pump (6), cooling q The power from the axle shaft is reduced in
pump (7), work equipment pump (8) and fan speed by final drives (15) and (20) and then
pump (9) to drive these pumps. transmitted to tires (17) and (22) through the
q Transmission (3) operates 6 hydraulic clutches planetary carrier.
through the solenoid valve-based operation of
the directional spool and gearshift spool to
select one of 4 gear speeds in the forward or
reverse travel direction.
Selection of a speed is done by use of the
electrically controlled switch.
2 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 3
SEN00705-03 10 Structure, function and maintenance standard
4 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Drive shaft 1
k Precautions for tightening torque of spider 3. For the above reason, when "retightening",
mounting bolts "removing" or "installing", be sure to replace
1. There are 2 types (new and old types) of the the existing bolts with new bolts and tighten
spider mounting bolts which have the same them to the torque specified for them.
part No. a A new part No. is set for the new bolt. For
a Different tightening torques are specified the new part No., see the parts book.
for the new bolt and old bolt.
3 *Spider mounting bolts (A, C, E):
2. Since the new and old bolts cannot be distin- 107 – 127 Nm {10.9 – 13 kgm}
guished from each other by appearances, the 3 Shaft mounting bolts (B, D, F):
existing spider mounting bolts cannot be 98 – 123 Nm {10 – 12.5 kgm}
reused. *: Bolts of new tightening torque (New bolt val-
a The specified torque for the new bolt is ues).
lower than that for the old bolt. Accord-
ingly, if the new bolt is tightened to the
torque for the old bolt, it may be broken
during operation and the machine may not
able to travel.
WA500-6 5
SEN00705-03 10 Structure, function and maintenance standard
6 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Outline
q The power from the engine is transmitted
through the torque converter, transmission and
transfer. From the transfer, part of the power is
then transmitted to the rear axle through rear
drive shaft (4). And the remaining portion of the
power is transmitted to the front axle through
center drive shaft (3), center support (2) and
front drive shaft (1).
q The drive shafts have the following purpose
besides simple power transmission.
q When the positions of the transmission and
front and rear axles change because of the
traveling impacts or working impacts during
articulation or travel of the machine, the drive
shaft absorbs the fluctuations in the angle and
length by use of the universal joint and slip
joint so that the power may be transmitted
without damaging the parts.
WA500-6 7
SEN00705-03 10 Structure, function and maintenance standard
1. Transmission
2. Torque converter
3. Transmission control valve
4. Power train pump
5. Torque converter oil cooler
6. Torque converter oil filter
8 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 9
SEN00705-03 10 Structure, function and maintenance standard
Torque converter 1
Without lockup clutch
(Torque converter, PTO, and input transfer)
10 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Specifications
WA500-6 11
SEN00705-03 10 Structure, function and maintenance standard
12 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Backlash between PTO idler
1 0.192 – 0.492
gear and PTO gear A
Backlash between PTO idler
2 0.192 – 0.492
gear and PTO gear B
Tolerance
Standard size
Shaft Hole
Tolerance for fitness
3 of bearing in PTO Outside –0.000 –0.010
100
gear A (Small) diameter –0.015 –0.045
Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026 Replace
Tolerance for fitness 150
diameter –0.018 –0.014
4 of bearing in PTO
gear A (Large) Inside +0.035 –0.000
85
diameter +0.013 –0.020
Outside –0.000 –0.010
Tolerance for fitness 100
diameter –0.015 –0.045
5 of bearing in PTO
gear B (Small) Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026
Tolerance for fitness 125
diameter –0.018 –0.014
6 of bearing in PTO
gear B (Large) Inside +0.030 –0.000
70
diameter +0.011 –0.015
WA500-6 13
SEN00705-03 10 Structure, function and maintenance standard
14 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.040 Repair by hard
80 79.92
–0.070 chromium-plating
Inside diameter of sleeve seal +0.030 or replace
65 65.1
ring contact surface –0.000
–0.01
2 Width 3 2.7
Wear of output shaft –0.03
Replace
seal ring Thick-
2.7 ±0.1 2.55
ness
Repair by hard
Inside diameter of PTO drive +0.040
3 170 170.5 chromium-plating
gear seal ring contact surface –0.000
or replace
Tolerance
Standard size
Shaft Hole
Tolerance for fitness
4 of PTO idler gear Outside –0.000 –0.028
125
bearing diameter –0.020 –0.068
Inside +0.012 –0.000
70
diameter –0.007 –0.015
Outside –0.000 –0.012
Tolerance for fitness diameter 150
–0.020 –0.052
5 of input transfer drive
gear bearing (Large) Inside +0.059 –0.000
85
diameter +0.037 –0.020
Outside –0.000 –0.012
Tolerance for fitness diameter 140
–0.020 –0.052
6 of input transfer drive
gear bearing (Small) Inside +0.051 –0.000
80
diameter +0.032 –0.015
Replace
Outside –0.000 –0.012
Tolerance for fitness 125
diameter –0.020 –0.052
7 of input transfer
driven gear bearing Inside +0.051 –0.000
80
diameter +0.032 –0.015
Backlash between PTO drive
8 0.192 – 0.492
gear and PTO idler gear
Backlash between input trans-
9 0.190 – 0.486
fer drive gear and driven gear
Standard clearance Clearance limit
Clearance between cage and
10 0.40 – 1.60
case of input transfer drive gear —
(Standard shim thickness: 1.0)
Clearance between cage and
0.60 – 1.80
11 case of input transfer driven —
(Standard shim thickness: 1.0)
gear
WA500-6 15
SEN00705-03 10 Structure, function and maintenance standard
q The power being transmitted to PTO drive gear (4) is then transmitted through PTO idler gear (5) and
PTO gear and then used as the pump driving power.
16 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Oil flow
WA500-6 17
SEN00705-03 10 Structure, function and maintenance standard
18 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Specifications
WA500-6 19
SEN00705-03 10 Structure, function and maintenance standard
20 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Backlash between PTO idler
1 0.192 – 0.492
gear and PTO gear A
Backlash between PTO idler
2 0.192 – 0.492
gear and PTO gear B
Tolerance
Standard size
Shaft Hole
Tolerance for fitness
3 of bearing in PTO Outside –0.000 –0.010
100
gear A (Small) diameter –0.015 –0.045
Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026 Replace
Tolerance for fitness 150
diameter –0.018 –0.014
4 of bearing in PTO
gear A (Large) Inside +0.035 –0.000
85
diameter +0.013 –0.020
Outside –0.000 –0.010
Tolerance for fitness 100
diameter –0.015 –0.045
5 of bearing in PTO
gear B (Small) Inside +0.030 –0.000
55
diameter +0.011 –0.015
Outside –0.000 +0.026
Tolerance for fitness 125
diameter –0.018 –0.014
6 of bearing in PTO
gear B (Large) Inside +0.030 –0.000
70
diameter +0.011 –0.015
WA500-6 21
SEN00705-03 10 Structure, function and maintenance standard
22 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.040 Repair by hard
80 79.92
–0.070 chromium-plating or
replace
Inside diameter of pilot seal ring +0.025
40 40.1
contact surface –0.000
2 –0.01
Wear of output shaft Width 3 2.7
–0.03 Replace
seal ring
Thickness 1.7 ±0.1 1.55
Repair by hard
Inside diameter of stator shaft seal +0.030
65 65.1 chromium-plating or
ring contact surface –0.000
replace
3
–0.01
Wear of output shaft Width 3 2.7
–0.03 Replace
seal ring
Thickness 2.7 ±0.1 2.55
Repair by hard
Inside diameter of PTO drive gear +0.040
4 170 170.5 chromium-plating or
seal ring contact surface –0.000
replace
Inside diameter of race free wheel
5 102.555 ±0.008 102.585
transfer surface
Inside diameter of stator shaft free +0.004
6 83.6 83.57
wheel transfer surface –0.009
Inside diameter of sliding portion of +0.015
7 83.71 83.79
bushing –0.000
8 Thickness of sliding portion of bushing 6 ±0.05 5.5
9 Thickness of clutch disc 5.4 ±0.1 4.9
Tolerance
Standard size
Shaft Hole
Tolerance for fitness of Outside –0.000 –0.028
10 125
PTO idler gear bearing diameter –0.020 –0.068
Inside +0.012 –0.000
70
diameter –0.007 –0.015
Outside –0.000 –0.012
Tolerance for fitness of 150
diameter –0.020 –0.052
11 input transfer drive gear
bearing (Large) Inside +0.059 –0.000
85 Replace
diameter +0.037 –0.020
Outside –0.000 –0.012
Tolerance for fitness of 140
diameter –0.020 –0.052
12 input transfer drive gear
bearing (Small) Inside +0.051 –0.000
80
diameter +0.032 –0.015
Outside –0.000 –0.012
Tolerance for fitness of 125
diameter –0.020 –0.052
13 input transfer driven
gear bearing Inside +0.051 –0.000
80
diameter +0.032 –0.015
Backlash between PTO drive gear
14 0.192 – 0.492
and PTO idler gear
Backlash between input transfer
15 0.190 – 0.486
drive gear and driven gear
Standard clearance Clearance limit
Clearance between cage and case
16 0.40 – 1.60
of input transfer drive gear —
(Standard shim thickness: 1.0)
Clearance between cage and case 0.60 – 1.80
17 —
of input transfer driven gear (Standard shim thickness: 1.0)
WA500-6 23
SEN00705-03 10 Structure, function and maintenance standard
Drive case (3) is disconnected from boss (9) and turbine (8) and lockup torque converter works as an ordi-
nary torque converter.
q The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and
PTO gear and then used as the pump driving power.
24 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Drive case (3) is connected to boss (9) and turbine (8) and lockup torque converter is locked up.
q The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and
PTO gear and then used as the pump driving power.
WA500-6 25
SEN00705-03 10 Structure, function and maintenance standard
Oil flow
26 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 27
SEN00705-03 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.050 +0.025 0.050 –
32 0.111
–0.066 +0.000 0.091
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
2 Valve spring length load load
205 N 195 N
126.6 106.5 122.8
{20.9 kg} {19.9 kg}
3. Spool Outline
4. Valve body q This valve is provided at the torque converter
outlet circuit in order to secure an optimum
A: From torque converter performance of the torque converter by adjust-
B: To oil cooler ing its set oil pressure.
C: Drain Set pressure:
D: Torque converter outlet port oil pressure pickup 0.42 ± 0.05 MPa {4.3 ± 0.5 kg/cm2}
port
28 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Operation
WA500-6 29
SEN00705-03 10 Structure, function and maintenance standard
Transmission 1
(Transmission, transfer and parking brake)
a Transmission with lockup clutch
30 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 31
SEN00705-03 10 Structure, function and maintenance standard
32 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 33
SEN00705-03 10 Structure, function and maintenance standard
34 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 35
SEN00705-03 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed
Free length Installed load Free length Installed load
1 R clutch spring (10 springs) length
48.1 N 41.2 N
77 70.2 72.4
{4.9 kg} {4.2 kg}
37.3 N 31.4 N
2 F clutch spring (10 springs) 77 71.7 72.4
{3.8 kg} {3.2 kg}
59.8 N 51.0 N
3 4th clutch spring (10 springs) 48.5 44.2 45.6
{6.1 kg} {5.2 kg}
94.1 N 80.4 N
4 3rd clutch spring (10 springs) 39.8 33 37.4
{9.6 kg} {8.2 kg}
67.7 N 57.9 N
5 2nd clutch spring (10 springs) 39.8 34.9 37.4
{6.9 kg} {5.9 kg}
110 N 93.2 N
6 1st clutch spring (10 springs) 46 39 43.2
{11.2 kg} {9.5 kg}
36 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Wear of 1st clutch cage Width –0.01
20 4.5 4.05
seal ring –0.03
Thickness 5.8 ±0.15 5.65
–0.01
Wear of output shaft Width 3.0 2.70
21 –0.03
seal ring
Thickness 3.1 ±0.1 2.95
–0.01
Wear of output shaft Width 2.5 2.25
22 –0.03
seal ring
Thickness 1.7 ±0.1 1.55
Backlash between sun R, F 0.13 – 0.32
23 gear and planetary pin-
ion 3rd, 2nd 0.12 – 0.33
WA500-6 37
SEN00705-03 10 Structure, function and maintenance standard
38 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outside diameter of coupling oil
1 –0.000 Repair by hard
seal contact surface (Rear) 105 104.8
–0.087 chromium-plating
Outside diameter of coupling oil –0.000 or replace
2 105 104.8
seal contact surface (Front) –0.087
Backlash between idler gear
3 0.19 – 0.48
and output gear
Tolerance
Standard size
Shaft Hole
Tolerance for fitness Outside –0.000 –0.000
4 180
of idler gear bearing diameter –0.025 –0.040
Inside +0.059 –0.000
100
diameter +0.037 –0.020
Outside –0.000 –0.014
Tolerance for fitness 190
diameter –0.030 –0.060
5 of output shaft bear-
Inside +0.059 –0.000 Replace
ing (Rear) 105
diameter +0.037 –0.020
Outside –0.000 –0.020
Tolerance for fitness 150
diameter –0.020 –0.040
6 of output gear bear-
ing (Front) Inside +0.045 –0.000
85
diameter +0.023 –0.020
Standard clearance Clearance limit
Clearance between cage and
7 0.63 – 1.37
case —
(Standard shim thickness: 1.0)
Clearance between cover and 0.48 – 1.32
8 —
cage (Standard shim thickness: 0.5)
WA500-6 39
SEN00705-03 10 Structure, function and maintenance standard
Disc clutch
Structure Operation
When clutch is “engaged” (fixed)
q Disc clutch is used for fixing ring gear (1). It q The oil from ECMV is sent with pressure to the
consists of piston (2), plate (3), disc (4), pin (5), rear side of piston (2) through the oil passage
return spring (6) and washer (8). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
40 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 41
SEN00705-03 10 Structure, function and maintenance standard
42 WA500-6
10 Structure, function and maintenance standard SEN00705-03
F ring gear (4) of F clutch and 1st hub (16) of 1st clutch are fixed hydraulically.
WA500-6 43
SEN00705-03 10 Structure, function and maintenance standard
44 WA500-6
10 Structure, function and maintenance standard SEN00705-03
F ring gear (4) of F clutch and 2nd ring gear (18) of 2nd clutch are fixed hydraulically.
WA500-6 45
SEN00705-03 10 Structure, function and maintenance standard
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd and 4th carrier (11)
O
3rd planetary pinion (12)
O
3rd sun gear (20)
O
Output shaft (23)
46 WA500-6
10 Structure, function and maintenance standard SEN00705-03
F ring gear (4) of F clutch and 4th ring gear (22) of 4th clutch are fixed hydraulically.
WA500-6 47
SEN00705-03 10 Structure, function and maintenance standard
48 WA500-6
10 Structure, function and maintenance standard SEN00705-03
R ring gear (7) of R clutch and 1st hub (16) of 1st clutch are fixed hydraulically.
WA500-6 49
SEN00705-03 10 Structure, function and maintenance standard
Transfer 1
Outline
q The transfer is installed in the output side of
the transmission and fixed to the transmission
case with the bolt.
Operation
50 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 51
SEN00705-03 10 Structure, function and maintenance standard
52 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 53
SEN00705-03 10 Structure, function and maintenance standard
54 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 55
SEN00705-03 10 Structure, function and maintenance standard
Outline
q The oil from the pump flows to the transmission control valve through the oil filter. Then oil flow is
divided into the main relief circuit and clutch actuation circuit.
q The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then
used to actuate the clutch and parking brake through the last chance filter. The oil relieved from the
main relief valve is supplied to the torque converter.
q When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according
to the command current from the transmission controller to reduce the gear shifting shocks. The ECMV
also keeps the clutch pressure constant during travel.
q If the F, R, or 1st – 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to
set the transmission in the desired gear speed.
q In the 2nd, 3rd and 4th speed travel, the lockup clutch ECMV operates at a speed higher than the speed
being specified from the transmission controller.
q There are 2 types of ECMV's used, which have the following distinctions and differences.
Fill switch
Printing on name plate
Flow detector valve (Operation pressure: Clutch used
(A)
MPa {kg/cm2})
Installed Installed
D******* F, R, 1st, 2nd, 3rd, 4th
(Without slit) 0.24 {2.45}
K******* Not installed Not installed L/U
56 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 57
SEN00705-03 10 Structure, function and maintenance standard
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
A: To clutch
P: From pump
T: Drain
Dr: Drain
P1: Clutch oil pressure pickup port
58 WA500-6
10 Structure, function and maintenance standard SEN00705-03
WA500-6 59
SEN00705-03 10 Structure, function and maintenance standard
60 WA500-6
10 Structure, function and maintenance standard SEN00705-03
q If a current is given to proportional solenoid (1) q If current flows in proportional solenoid (1), the
while there is no oil in the clutch, a hydraulic solenoid generates thrust in proportion to the
force balanced with the solenoid force is current. This thrust of the solenoid is balanced
applied to chamber (B) and it pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the left. This conducts oil pressure in clutch port and the repulsive force
through pump port (P) and orifice (a) of flow of pressure control valve spring (2), and thus
rate pickup valve (4) to start filling the oil to the the pressure is settled.
clutch chamber. At this time, differential pres-
sure is generated between the upper stream
and down stream of orifice (a) of flow rate
pickup valve (4). This differential pressure
pushes flow rate pickup valve (4) leftward. As
the clutch chamber is filled up with oil and oil
flow from pump port (P) to clutch port (A) is
stopped, differential pressure before and after
orifice (a) of flow rate pickup valve (4) disap-
pears. As the result, flow rate pickup valve (4)
is pushed rightward, turning “ON” fill switch (5).
WA500-6 61
SEN00705-03 10 Structure, function and maintenance standard
A: To clutch
P: From pump
T: Drain
Dr: Drain
P1: Clutch oil pressure pickup port
62 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Outline
ECMV for lockup clutch
q This valve is used to switch the clutch in order
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
WA500-6 63
SEN00705-03 10 Structure, function and maintenance standard
Operation
When clutch is “disengaged” (released) When clutch is “engaged” (fixed)
64 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between main relief size Shaft Hole clearance limit
1
vale and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 +0.000 0.058
Clearance between torque con- –0.035 +0.013 0.035 –
2 22 0.078
verter relief vale and valve body –0.045 +0.000 0.058
Standard size Repair limit
Installed Installed Installed Replace
Main relief valve spring Free length Free length
3 length load load
(Outside)
479.1 N 456 N
128 78.3 124.2
{48.9 kg} {46.5 kg}
365.5 N 347 N
4 Main relief valve spring (Inside) 108 78.3 104.8
{37.3 kg} {35.4 kg}
Torque converter relief valve 134.3 N 127 N
5 50 43 48.5
spring {13.7 kg} {13.0 kg}
WA500-6 65
SEN00705-03 10 Structure, function and maintenance standard
Operation
66 WA500-6
10 Structure, function and maintenance standard SEN00705-03
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 +0.000 0.058
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
2 Valve spring length load load
97.4 N 92.6 N
59.7 37 57.9
{9.94 kg} {9.44 kg}
WA500-6 67
SEN00705-03
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
68
SEN00864-02
WA500-6
WA500-6 1
SEN00864-02 10 Structure, function and maintenance standard
2 WA500-6
10 Structure, function and maintenance standard SEN00864-02
1. Relief valve
2. Element
3. Drain plug
A: Inlet port
B: Outlet port
WA500-6 3
SEN00864-02 10 Structure, function and maintenance standard
Specifications
q Filtering area : 8,900 cm2 x 2
q Relief pressure : 0.32 MPa {3.25 kg/cm2}
Operation
q Oil from the torque converter charge pump
enters filter inlet port (A). It passes from out-
side to inside of element (2), and flows to outlet
port (B).
4 WA500-6
10 Structure, function and maintenance standard SEN00864-02
WA500-6 5
SEN00864-02 10 Structure, function and maintenance standard
Center support 1
6 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between case and size Shaft Hole clearance limit
1
bearing –0.000 –0.036 –0.018 –
140 –0.015
–0.018 –0.061 –0.061
Clearance between case and –0.000 –0.036 –0.018 – Replace
2 130 –0.015
bearing –0.018 –0.061 –0.061
Clearance between coupling +0.051 –0.000 –0.032 –
3 80 –0.029
shaft and bearing +0.032 –0.015 –0.066
Clearance between coupling +0.051 –0.000 –0.032 –
4 75 –0.029
shaft and bearing +0.032 –0.015 –0.066
Standard size Tolerance Repair limit
Wear of oil seal contact sur-
5 –0.000 Repair by chro-
face 95 –0.18
–0.087 mium-plating or
Wear of oil seal contact sur- –0.000 replace
6 105 –0.18
face –0.087
7 End play of coupling shaft Preload 3.9 Nm {0.4 kgm} max. Replace
WA500-6 7
SEN00864-02 10 Structure, function and maintenance standard
Axle 1
Front axle
8 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Rear axle
WA500-6 9
SEN00864-02 10 Structure, function and maintenance standard
Differential 1
Front differential
10 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Front differential
(with limited slip differential)
WA500-6 11
SEN00864-02 10 Structure, function and maintenance standard
Rear differential
12 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Rear differential
(with limited slip differential)
WA500-6 13
SEN00864-02 10 Structure, function and maintenance standard
14 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance in side bearing outer size Shaft Hole clearance limit
1
race of differential gear assembly –0.000 +0.012 –0.013 –
200 —
–0.015 –0.013 0.027
Clearance in side bearing inner +0.090 –0.000 –0.065 –
2 130 —
race of differential gear assembly +0.065 –0.025 –0.115
Clearance in outer race of bevel –0.000 –0.050 –0.020 –
3 215 —
pinion shaft bearing –0.030 –0.079 –0.079
Clearance in inner race of bevel +0.045 –0.000 –0.023 –
4 100 —
pinion shaft bearing +0.023 –0.020 –0.065
Clearance in outer race of bevel +0.21 +0.063 –0.037 –
5 165 —
pinion shaft bearing +0.10 –0.000 –0.21
Clearance in inner race of bevel +0.039 –0.000 –0.020 –
6 75 —
pinion shaft bearing +0.020 –0.015 –0.054 Replace
Clearance between differential –0.018 +0.057 0.018 –
7 320 —
carrier and cage –0.075 –0.000 0.132
Clearance between spider and dif- –0.13 +0.03 0.021 –
8 40 —
ferential pinion bushing –0.18 –0.02 –0.11
Clearance between pinion and dif- –0.025 +0.03 0.005 –
9 46
ferential pinion bushing –0.050 –0.02 0.080
10 Backlash of bevel gear 0.30 – 0.45
11 Backlash of differential gear 0.36 – 0.51
12 End play of bevel pinion gear Max. 0.64
Free rotational torque of bevel
13 Max. 8.34 Nm {0.85 kgm}
gear
14 Rear runout of bevel gear 0.1
15 Clearance between bolt and cap 0.08 – 0.13
WA500-6 15
SEN00864-02 10 Structure, function and maintenance standard
16 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Unit: mm
No Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thickness of side gear washer
4 ±0.05 3.8
Thickness of bevel pinion gear Replace
2 3 ±0.08 1.35
washer
0
3 Wear of oil seal contact surface 105 —
–0.087
WA500-6 17
SEN00864-02 10 Structure, function and maintenance standard
18 WA500-6
10 Structure, function and maintenance standard SEN00864-02
1. Washer
2. Disc
3. Plate
4. Pressure ring
5. Cover
6. Shaft
7. Side gear
8. Shaft
9. Case
10. Pinion
11. Bevel gear
WA500-6 19
SEN00864-02 10 Structure, function and maintenance standard
20 WA500-6
10 Structure, function and maintenance standard SEN00864-02
2. When drive forces of right and left wheels Difference of wheel drive force in each type of dif-
are unbalanced ferential when either wheel slips
[When the road conditions (coefficients of friction)
Wheel drive force
under both wheels and the wheel loads are uneven (Drive force of slipping wheel is 1)
and either wheel slips more easily]
Slipping Locked Total
Example 1: When either wheel is on soft ground in
wheel wheel (Ratio)
digging work
Example 2: When either wheel is on snow and the Limited slip differential
1 2.64 3.64 (1.82)
(if equipped)
other one is on asphalt in snow remov-
ing work Ordinary differential 1 1 2 (1)
Example 3: When the right and left wheel loads are
unbalanced in travel on a slope On a road where either wheel slips easily, the drive
force of the limited slip differential is 1.82 times as
The power from the transmission is distributed large as that of the ordinary differential.
evenly by the differential gears to the right and left.
If the distributed drive force limits the wheel slip <While machine is turning>
limit on the slipping side, the excess of the drive The differential gears in the limited slip differential
force is transmitted through the brake on the back operate similarly to those in the ordinary differential.
side of the side gear and the case to the brake on Accordingly, a difference in rotation speed between
the opposite side (locked side) and given to the the outer and inner tires necessary for turning is
locked wheel. generated smoothly.
Only when the excessive drive force exceeds the
braking force, the differential starts working.
WA500-6 21
SEN00864-02 10 Structure, function and maintenance standard
22 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance in side bearing outer size Shaft Hole clearance limit
1
race of differential gear assembly –0.000 +0.012 –0.013 –
200 —
–0.015 –0.013 0.027
Clearance in side bearing inner +0.090 –0.000 –0.065 –
2 130 —
race of differential gear assembly +0.065 –0.025 –0.115
Clearance in outer race of bevel –0.000 –0.050 –0.020 –
3 215 —
pinion shaft bearing –0.030 –0.079 –0.079
Clearance in inner race of bevel +0.045 –0.000 –0.023 –
4 100 —
pinion shaft bearing 0.023 –0.020 –0.065
Clearance in outer race of bevel +0.21 +0.063 –0.037 –
5 165 —
pinion shaft bearing +0.10 –0.000 –0.21
Clearance in inner race of bevel +0.039 –0.000 –0.020 –
6 75 —
pinion shaft bearing +0.020 –0.015 –0.054
Clearance between differential –0.018 +0.057 0.018 –
7 320 —
carrier and cage –0.075 –0.000 0.132
8 Backlash of bevel gear 0.30 – 0.45
9 Backlash of differential gear 0.36 – 0.51
Replace
10 End play of bevel pinion gear Max. 0.64
Free rotational torque of bevel
11 Max. 8.34 Nm {0.85 kgm}
gear
12 Rear runout of bevel gear 0.1
13 Clearance between bolt and cap 0.08 – 0.13
Standard size Tolerance Repair limit
14 Thickness of plate 3.4
±0.02 3.6
3.5
15 Thickness of disc 3.2 ±0.07 3.915
Clearance between disc and plate
16 0.2 – 0.8
(end play)
Standard size Tolerance Repair limit
3.75
17 Thickness of washer
4.0 ±0.05 3.8
4.25
Wear of coupling seal sliding sur- 0
18 105 —
face –0.087
WA500-6 23
SEN00864-02 10 Structure, function and maintenance standard
Final drive 1
1. Axle shaft
2. Sun gear (Number of teeth: 17)
3. Ring gear (Number of teeth: 70)
4. Planetary carrier
5. Planetary gear (Number of teeth: 26)
6. Wheel
24 WA500-6
10 Structure, function and maintenance standard SEN00864-02
WA500-6 25
SEN00864-02 10 Structure, function and maintenance standard
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between planetary size Shaft Hole clearance limit
1
shaft and bearing +0.029 +0.013 –0.003 –
50.8 —
+0.016 +0.000 –0.029
Clearance between ring gear hub +0.063 +0.025 –0.009 –
2 220.662 —
and bearing +0.034 +0.000 –0.063
Thickness of ring gear mounting Standard size Tolerance Repair limit
3
retainer 22 ±0.1 21.6
Backlash of planetary gear and
4 0.19
sun gear
Backlash of planetary gear and Replace
5 0.20
ring gear
Standard shim thickness of wheel
6 2.3
hub
Standard Tolerance Standard Clearance
Clearance between wheel hub size Shaft Hole clearance limit
7
and bearing +0.051 –0.036 –0.036 –
314.325 —
+0.000 –0.068 –0.119
Clearance between tube and –0.045 +0.072 0.045 –
8 190 —
bearing –0.074 +0.000 0.146
Clearance between wheel hub +0.000 –0.063 –0.059 –
9 260 —
and bearing –0.004 –0.095 –0.095
26 WA500-6
10 Structure, function and maintenance standard SEN00864-02
Outline
q Final drive is reduced by the planetary gear
unit in order to gain increased force, and then
drive force is transmitted to the tires.
Operation
q Power transmitted from the differential mecha-
nism to sun gear (2) through axle shaft (1) is
transmitted to planetary gear (5). The plane-
tary gear rotates inside fixed ring gear (3) to
transmit reduced rotation to planetary carrier
(4) and the power is transmitted to wheel (6)
mounted onto the planetary carrier.
WA500-6 27
SEN00864-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
28
SEN00706-03
WA500-6
WA500-6 1
SEN00706-03 10 Structure, function and maintenance standard
Steering system 1
Steering piping diagram 1
2 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Steering column 1
1. Steering wheel
2. Steering column
3. Joint
4. Steering valve
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between steering size Shaft Hole clearance limit
5 Replace
shaft and column bearing –0.00 +0.15
19 0.05 – 0.23 0.4
–0.08 +0.05
WA500-6 3
SEN00706-03 10 Structure, function and maintenance standard
4 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Installed Installed Allowable
Free length Free length
1 Steering spool return spring length load load
56.9N 45.1N
37.2 32.0 —
{5.8kg} {4.6kg}
2.9N 2.5N Replace
2 Load check valve spring 20.9 18.3 —
{0.30kg} {0.25kg}
147.1N 120.6N
3 Unload spool return spring 69.7 68.5 —
{15.0kg} {12.3kg}
182.4N 145.1N
4 Relief valve spring 24.0 22.19 —
{18.6kg} {14.8kg}
WA500-6 5
SEN00706-03 10 Structure, function and maintenance standard
6 WA500-6
10 Structure, function and maintenance standard SEN00706-03
WA500-6 7
SEN00706-03 10 Structure, function and maintenance standard
8 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Turning right
WA500-6 9
SEN00706-03 10 Structure, function and maintenance standard
Turning left
10 WA500-6
10 Structure, function and maintenance standard SEN00706-03
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
q The steering relief valve is contained in the
steering valve. This valve is used to set the
maximum pressure of the steering circuit for
the steering valve in operation. If the pressure
of the steering circuit increases beyond the
relief valve-specified level while the steering
valve is in operation, oil is relieved from this
valve. Above relief activates the spool of the
demand valve, draining the oil to the steering
circuit.
WA500-6 11
SEN00706-03 10 Structure, function and maintenance standard
12 WA500-6
10 Structure, function and maintenance standard SEN00706-03
1. Poppet
2. Safety valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring q Opening of pilot poppet (4) decreases pres-
sure on the backside of poppet (1), starting
Function move of poppet (1). By this move, pilot poppet
q The safety valve installed on the steering valve (4) is seated in its place.
has two functions. One is the safety valve func-
tion that is used to protect the steering cylinder
or hydraulic piping from damages when an
abnormal pressure is generated due to some
sort of impacts applied to the steering cylinder
while the steering valve is at neutral. In such
case, abnormal pressure is relieved from this
valve. The other is the suction valve function.
This function prevents vacuum state to emerge
in the circuit when negative pressure is gener-
ated on the steering cylinder side.
Operation
Operation of safety valve
q Port (A) and port (B) are connected to the cyl- q Since the inside pressure is lower than that of
inder circuit and drain circuit, respectively. port (A), safety valve poppet (2) opens. As the
After being conducted through poppet (1) hole, result, the oil is conducted from port (A) to port
the oil works on the different areas of diameter (B) and abnormally high pressure is prevented
(d1) and (d2). Check valve poppet (3) and from being generated.
safety valve poppet (2) are securely seated.
WA500-6 13
SEN00706-03 10 Structure, function and maintenance standard
14 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Steering valve 1
WA500-6 15
SEN00706-03 10 Structure, function and maintenance standard
Outline Structure
q The steering valve is directly connected to the q Spool (9) is directly connected to the drive
shaft of the steering wheel. The steering wheel shaft of the steering wheel. It is also connected
operation activates the steering valve using the to sleeve (8) through center pin (7) (it is
oil from PPC pump as the pilot pressure. The detached from the spool when the steering
oil from the steering valve is conducted, wheel is at “neutral“) and centering spring.
through the steering valve, to either of the left q The top of drive shaft (3) is engaged with cen-
and right steering cylinders to determine the ter pin (7) and thus combined with sleeve (8).
machine travelling direction. And the bottom is engaged with the spline of
q The steering valve is roughly divided into spool rotor (5) of Gerotor set.
(9) and sleeve (8) which has the rotary select- q Valve body (4) has 4 ports. These ports are
ing function. This valve is used being config- respectively connected to the pump circuit,
ured with Gerotor set (combination of rotor (5) tank circuit, steering cylinder head side and
and stator (10)). In the normal steering opera- bottom side. And the ports on the pump side
tion, this set functions as a hydraulic motor. and tank side are connected to the check valve
And if supply of oil is stopped due to a failure in the body. If the pump or engine fails, this
on the steering pump or engine, it functions as check valve allows to suction oil directly from
a hand pump to supply pilot pressure to the the tank.
steering valve.
16 WA500-6
10 Structure, function and maintenance standard SEN00706-03
WA500-6 17
SEN00706-03 10 Structure, function and maintenance standard
18 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Stop valve 1
1. Boot
2. Wiper
3. Seal
4. Poppet
5. Spring
6. Spool
7. Spring
WA500-6 19
SEN00706-03 10 Structure, function and maintenance standard
20 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Steering cylinder 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between steering size clearance limit
Shaft Hole
1 cylinder rod, bushing at frame
connection and mounting pin –0.000 +0.174 0.100 –
65 —
–0.074 +0.100 0.248 Replace
Clearance between steering
cylinder bottom, bushing at –0.000 +0.174 0.100 –
2 65 —
frame connection and mount- –0.074 +0.100 0.248
ing pin
Standard
clearance
Steering cylinder and front Boss width Hinge width
3 (Clearance After shim adjust-
frame connection between a + b) ment
75 ± 1.2 79 ± 1 1.8 – 6.2 Max. 0.5
Steering cylinder and rear frame
4 75 ± 1.2 79 ± 1 1.8 – 6.2
connection
WA500-6 21
SEN00706-03 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between pistion rod size Shaft Hole clearance limit Replace pin and
1
and bushing –0.030 +0.151 0.024 – bushing
60 0.527
–0.076 –0.006 0.227
Tightening torque of cylinder
2 785 ± 78.5 Nm {80 ± 8.0 kgm}
head
Tightening torque of cylinder
3 1,770 ± 180 Nm {180 ± 18.0 kgm} (Width across flat: 60 mm) Retighten
piston
Tightening torque of cylinder
4 9.8 - 12.74 Nm {1.0 - 1.3 kgm}
head port side plug
22 WA500-6
10 Structure, function and maintenance standard SEN00706-03
WA500-6 23
SEN00706-03 10 Structure, function and maintenance standard
1. Diverter valve
2. Steering pump
3. Hydraulic tank
4. Emergency steering pump
5. Transmission
24 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Diverter valve 1
(for emergency steering)
WA500-6 25
SEN00706-03 10 Structure, function and maintenance standard
Function
q In a case where steering is disabled due to
engine stop or steering pump seizure during
machine traveling, this function enables opera-
tion of the steering wheel, utilizing rotations of
the transmission to operate the emergency
steering pump.
26 WA500-6
10 Structure, function and maintenance standard SEN00706-03
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between body and size Shaft Hole clearance limit
1
spool –0.008 +0.015 0.017 –
26 —
–0.012 +0.009 0.027
Standard size Repair limit
Installed Installed Installed
Free length Free length Replace
2 Spool return spring length load load
91.2 N 86.3 N
92 64 90.5
{9.3 kg} {8.8 kg}
4.0 N 3.8 N
3 Check valve spring 54.4 38 37.4
{0.41 kg} {0.39 kg}
1.96 N 1.84 N
4 Check valve spring 54.5 46.5 53.6
{0.2 kg} {0.19 kg}
WA500-6 27
SEN00706-03 10 Structure, function and maintenance standard
Operation
q If the pump and engine are normal
28 WA500-6
10 Structure, function and maintenance standard SEN00706-03
WA500-6 29
SEN00706-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
30
SEN00707-03
WA500-6
WA500-6 1
SEN00707-03 10 Structure, function and maintenance standard
Brake system 1
Brake piping diagram 1
2 WA500-6
10 Structure, function and maintenance standard SEN00707-03
WA500-6 3
SEN00707-03 10 Structure, function and maintenance standard
Brake valve 1
A: To front brake
B: To rear brake
PA: From accumulator charge valve ACC1 port
PB: From accumulator charge valve ACC2 port
TA: Drain port
TB: Drain port
1. Rod
2. Piston
3. Spool (for rear)
4. Spool (for front)
Unit: mm
Standard size Repair limit
No Check item Free Installed Free Installed Remedy
Installed load Installed load
length length length length
95.8 N
5 Return spring 71.7 58.6 66.1 — —
{9.77 kg}
22.8 N
6 Control spring 11 10 — — —
{2.32 kg}
41.1 N
7 Control spring 51.2 49.7 — — — Replace
{4.19 kg}
8 Control spring 31 — — — — —
9 Control spring 23.5 — — — — —
17.2 N
10 Return spring 40.1 27.5 — — —
{1.75 kg}
4 WA500-6
10 Structure, function and maintenance standard SEN00707-03
Outline Operation
q The brake valve is installed in the lower front When brake operated
side of the operator's seat. Pressing the brake q Pedal (1) pressing effort is transmitted to spool
pedal conducts oil to the brake piston, operat- (4) through rod (2), piston (3) and spring (5).
ing the brake. q As spool (4) is pushed to the right, disconnect-
q The left side and right side brake pedals are ing between port (A) and port (T) and the oil
mechanically interlocked. Pressing one of the from the pump and accumulator is conducted
pedals operates another pedal at the same to port (A) through port (PA) to operate the
time. front brake cylinder.
q And working with the transmission cut-off q If pedal (1) is pressed, the pressing effort is
switch, they operate the transmission control transmitted through rod (2) and spring (5) to
valve electrically to set the transmission to the spool (4).
neutral position. q The pressing effort transmitted to spool (4) is
further transmitted through plunger (6) to spool
(5).
q As spool (6) is pushed to the right, cutting off
connection between port (B) and port (T). The
oil from the pump and accumulator is con-
ducted to port (B) through port (PB) to operate
the rear brake cylinder.
WA500-6 5
SEN00707-03 10 Structure, function and maintenance standard
6 WA500-6
10 Structure, function and maintenance standard SEN00707-03
Balancing operation
q If the front brake cylinder is filled up with oil q Since port (B) is kept disconnected from port
and oil pressure between port (PA) and port (T), the brake is kept operated by the oil pres-
(A) becomes higher, the oil is conducted from sure applied to the brake cylinder.
orifice (e) of spool (4) to chamber (E). q The operating force of the front brake circuit
q The oil pushes spool (4) resisting against (port A side) is balanced against the pedal
spring (5), disconnecting ports (PA) and (A). pressing effort and the operating force of the
q Since port (A) is kept disconnected from port rear brake circuit (port B side) is balanced
(T), the brake is kept operated by the oil pres- against that of the front brake circuit (port A
sure applied to the brake cylinder. side).
q If ports (PA) and (A) of spool (4) are discon- q When spools (4) and (6) are moved to the
nected, the front brake cylinder is filled with the stroke end, ports (PA) and (A) connected com-
oil and the pressure in the line between ports pletely, and ports (PB) and (B) are also con-
(PB) and (B) rises simultaneously, and then the nected completely. As a result, the oil pressure
oil flows through orifice (f) of spool (6) to cham- in the front and rear brake cylinders is equal to
ber (F). the oil pressure from the pump.
q The oil pushes up spool (6) by the moving dis- q The braking force can be adjusted by adjusting
tance of spool (4) and disconnects port (PB) the pedal pressing effort until spools (4) and
from port (B). (6) are moved to the stroke end.
WA500-6 7
SEN00707-03 10 Structure, function and maintenance standard
As brake is released
q If pedal (1) is released, the operating pressure q At the same as spool (4) was pushed back,
being applied to spool (4) is reduced, and spool (6) is also pushed back by the back pres-
spool (4) is pushed back by the back pressure sure on the brake cylinder and the spool return
on the brake cylinder and the tension of the spring tension.
spool return spring. q Ports (B) and (T) are connected and the back
q Ports (A) and (T) are connected and the back pressure oil on the brake cylinder is drained
pressure oil on the brake cylinder is drained through port (T), thus the rear brake is
through port (T), thus the front brake is released.
released.
8 WA500-6
10 Structure, function and maintenance standard SEN00707-03
Slack adjuster 1
1. Cylinder Function
2. Check valve q The slack adjuster is installed on the brake oil
3. Piston line leading to the brake piston from the brake
4. Spring valve, and functions to keep the time lag during
5. Bleeder brake operation at a fixed level.
WA500-6 9
SEN00707-03 10 Structure, function and maintenance standard
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between body and size Shaft Hole clearance limit
6
piston –0.030 +0.074 0.030 –
55 0.25
–0.076 +0.000 0.150
Standard size Repair limit
Installed Installed Allowable Replace
Free length Free length
7 Slack adjuster spring length load load
39.2 N
198 60
{4.0 kg}
66.7 N
8 Spring 39.2 33
{6.8 kg}
10 WA500-6
10 Structure, function and maintenance standard SEN00707-03
WA500-6 11
SEN00707-03 10 Structure, function and maintenance standard
12 WA500-6
10 Structure, function and maintenance standard SEN00707-03
WA500-6 13
SEN00707-03 10 Structure, function and maintenance standard
14 WA500-6
10 Structure, function and maintenance standard SEN00707-03
WA500-6 15
SEN00707-03 10 Structure, function and maintenance standard
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Function
q The PPC relief valves are located between the
EPC brake pump and the EPC valve and
between work equipment units. When the PPC
valve is not operating, or when any abnormal
pressure has occurred in the EPC circuit, oil
from the pump is relieved from this valve in
order to protect the pump and the circuit from
damage.
16 WA500-6
10 Structure, function and maintenance standard SEN00707-03
Operation
q The relief valve is installed on the charge q When pressure at port (B) drops, the orifice of
valve. Port (A) is connected to the pump cir- main valve (1) functions so as to allow pres-
cuit, and port (C), to the drain circuit. sure differential to occur at ports (A) and (B),
Oil runs through the orifice of main valve (1) causing main valve (1) to open due to pressure
and fills port (B). from port (A) and oil in port (A) is drained to
Pilot poppet (4) is seated on valve seat (3). port (C) for relief.
q When pressure at ports (A) and (B) reaches
the set pressure, pilot poppet (4) opens and oil
pressure at port (B) is carried from port (D) to
port (C), causing pressure at port (B) to drop.
WA500-6 17
SEN00707-03 10 Structure, function and maintenance standard
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (3) and free piston (4) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine stops by utilizing
its compressibility.
18 WA500-6
10 Structure, function and maintenance standard SEN00707-03
WA500-6 19
SEN00707-03 10 Structure, function and maintenance standard
Brake 1
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc
20 WA500-6
10 Structure, function and maintenance standard SEN00707-03
WA500-6 21
SEN00707-03 10 Structure, function and maintenance standard
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Installed Installed Allowable
Free length Free length
9 Return spring length load hole load
452N 338N
104.8 96.5 102.7
{46kg} {35.0kg}
Standard size Tolerance Repair limit
10 Plate thickness
2.4 — 2.15
11 Thickness of disc 5.1 — 4.6
Assembled thickness of plate
12 62.4 — 56.15
discs
–0.000
13 Wear of seal contact surface 430 — Replace
–0.155
Wear of piston seal contact sur- +0.097
14 420 —
face +0.000
Wear of piston seal contact sur- +0.097
15 455 —
face +0.000
Standard strain Repair limit
16 Strain of plate contact surface
0.5 0.7
17 Strain of disc contact surface 0.45 0.65
Backlash of outer gear and
18 0.179 – 0.713
plate
19 Backlash of inner gear and disc 0.165 – 0.522
Function
q All the 4 wheels are equipped with a main q When the brake pedal is released, back pres-
brake, which is a wet-type multi-disc brake. sure on brake piston (4) is released and force
q When the brake pedal is pressed down, pres- of return spring (2) moves the piston in the
sure oil from the slack adjuster moves brake direction shown by an arrow mark to release
piston (4) in the direction shown by an arrow the brake.
mark to press disc (8) to contact plate (7). This
generates friction force between the disc and
the plate. While the wheel is rotating with the
disc, this friction causes the machine to slow
down and stop.
22 WA500-6
10 Structure, function and maintenance standard SEN00707-03
Outline
q The parking brake is installed at the output q The neutralizer relay cuts off current to the
shaft with the wet-type multi-disc brake being transmission solenoid valve as long as opera-
built in the transmission. Using the pressing tion of the parking brake is continued in order
force of the spring, it mechanically operates to to maintain the transmission at the neutral.
relieve the oil pressure. q Parking brake emergency release switch (2) is
q If parking brake switch (1) installed to the oper- provided to move a machine currently being
ator's cab is turned “ON”, parking brake sole- stopped due to an engine or drive system trou-
noid valve (4) installed to transmission control ble (parking brake of the machine is enabled).
valve (3) shuts off the oil pressure and the
parking brake is applied. If parking brake
switch (1) is turned “OFF”, the hydraulic force
in the cylinder releases the parking brake.
WA500-6 23
SEN00707-03 10 Structure, function and maintenance standard
Parking brake 1
24 WA500-6
10 Structure, function and maintenance standard SEN00707-03
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
9 Parking brake spring (outside) length load load
1,266 N 1,203 N
94 72.6 91.2
{129.2 kg} {122.7 kg}
662 N 630 N
10 Parking brake spring (inside) 94 72.6 91.2
{67.6 kg} {64.2 kg}
Standard size Tolerance Repair limit Replace
Thick- 4.0 ±0.05 3.9
11 Plate
ness 7.0 ±0.05 6.9
Strain — 0.05 0.6
Thick-
12 Disc 3.2 ±0.08 2.97
ness
Load of wave spring 626.4 N ±176.5 N 533 N
13
(testing height: 3.2 mm) {63.9 kg} {±18 kg} {54.3 kg}
WA500-6 25
SEN00707-03 10 Structure, function and maintenance standard
26 WA500-6
10 Structure, function and maintenance standard SEN00707-03
Operation
q As the parking brake switch is turned “ON”, the q If the parking brake switch is turned “OFF”, the
solenoid is turned “OFF”. As the result, spool solenoid is turned “ON” and spool (1) is moved
(1) is pushed back in the left direction by the to the right.
tension of spring (2). q The pressurized oil from the pump flows to the
q Pump port (P) is disconnected from parking parking brake through port (P), inside of spool
brake port (A), stopping flow of the pressurized (1) and port (A). At the same time, port (T) is
oil from the pump to the parking brake. At the closed and the oil is not drained.
same time, the oil that was working as back q As oil pressure is applied to the back side of
pressure of the parking brake is drained the piston, it compresses the spring, separat-
through port (A) and port (T). ing the plate and disc from each other. As the
q As the back pressure of the piston is drained, result, the parking brake is released.
the piston being pushed back by the spring
contacts the plate and disc closely to enable
the parking brake.
WA500-6 27
SEN00707-03 10 Structure, function and maintenance standard
1. Valve
2. Solenoid valve
A: To parking brake
B: From parking brake valve
C: From pilot circuit
T: Drain
P: From brake valve (accumulator circuit)
Function
q The emergency release solenoid valve is
installed between the transmission and trans-
mission control. It operates solenoid of the
parking brake release switch installed at the
operator's seat when oil pressure is not avail-
able from the power train pump due to engine
failure, etc. in order to supply accumulator
charge pressure in the brake circuit to the
parking brake.
28 WA500-6
10 Structure, function and maintenance standard SEN00707-03
WA500-6 29
SEN00707-03
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 07-19 (01)
30
SEN00708-01
WA500-6
WA500-6 1
SEN00708-01 10 Structure, function and maintenance standard
2 WA500-6
10 Structure, function and maintenance standard SEN00708-01
WA500-6 3
SEN00708-01 10 Structure, function and maintenance standard
4 WA500-6
10 Structure, function and maintenance standard SEN00708-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between hole and size clearance limit
Shaft Hole
1 shaft on front support side (after
press-fitting of bushing) –0.056 +0.489 0.056 –
310 1.6
–0.137 +0.000 0.626
Clearance between hole and Replace
+2.300 +0.089 (Bushing is
2 shaft on front support side 320.2 — —
+0.800 +0.000 adhered to sup-
(before press-fitting of bushing)
port on both front
Clearance between hole and
–0.056 +0.481 0.048 – and rear.)
3 shaft on rear support side (after 260 1.6
–0.137 –0.008 0.618
press-fitting of bushing)
Clearance between hole and
+2.300 +0.089
4 shaft on rear support side 270.2 — —
+0.800 +0.000
(before press-fitting of bushing)
Standard size Tolerance Repair limit
5 Thickness of thrust plate –0.10
22 —
–0.25
+0.1 Replace
6 Thickness of thrust washer 5 —
–0.3
7 Thickness of rear bushing 5 ±0.1 —
8 Thickness of front bushing 5 ±0.1 —
WA500-6 5
SEN00708-01 10 Structure, function and maintenance standard
6 WA500-6
10 Structure, function and maintenance standard SEN00708-01
WA500-6 7
SEN00708-01 10 Structure, function and maintenance standard
8 WA500-6
10 Structure, function and maintenance standard SEN00708-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between upper hinge size Shaft Hole clearance limit
1
pin and rear frame –0.036 +0.054 0.036 –
100 —
–0.058 +0.000 0.112
Clearance between upper hinge –0.036 +0.054 0.036 –
2 100 —
pin and spacer (small) –0.058 +0.000 0.112
Clearance between upper hinge –0.036 –0.000 0.016 –
3 100 —
pin and bearing –0.058 –0.020 0.058
Clearance between upper hinge –0.036 +0.054 0.036 –
4 100 —
pin and spacer (large) –0.058 +0.000 0.112
Clearance between rear frame –0.043 +0.063 0.043 –
5 130 —
and spacer (large) –0.106 +0.000 0.169
Clearance between front frame –0.000 –0.048 –0.023 –
6 155 —
and lower hinge bearing –0.025 –0.088 –0.088
Clearance between lower hinge –0.036 +0.054 0.036 –
7 100 —
pin and bushing –0.058 +0.000 0.112
Clearance between lower hinge –0.036 –0.000 0.016 –
8 100 —
pin and bearing –0.058 –0.020 0.058
Clearance between front frame –0.000 –0.050 –0.025 –
9 160 — Replace
and upper hinge bearing –0.025 –0.090 –0.090
Clearance between lower hinge –0.043 +0.063 0.043 –
10 125 —
rear frame and bushing –0.083 +0.000 0.146
Clearance in seal fitting part of +0.280 +0.054 –0.126 –
11 115 —
lower hinge +0.180 +0.000 –0.280
Clearance in seal fitting part of +0.310 +0.063 –0.147 –
12 135 —
upper hinge pin +0.210 +0.000 –0.310
Height of upper hinge pin Standard size Tolerance Repair limit
13
spacer (small) 35 ±0.1 —
Height of upper hinge pin
14 101.5 ±0.1 —
spacer (large)
Standard thickness of shim
15 between upper hinge and 2.3
retainer
Standard thickness of shim
16 between upper hinge and 1.6
retainer
Standard thickness of shim
17 between lower hinge and 1.6
retainer
WA500-6 9
SEN00708-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
10
SEN00709-02
WA500-6
WA500-6 1
SEN00709-02 10 Structure, function and maintenance standard
2 WA500-6
10 Structure, function and maintenance standard SEN00709-02
WA500-6 3
SEN00709-02 10 Structure, function and maintenance standard
4 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Hydraulic tank 1
WA500-6 5
SEN00709-02 10 Structure, function and maintenance standard
1. Body
2. Filter element
3. Poppet
4. Sleeve
Function
q Prevention of negative pressure in tank
Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated. At this time, poppet (3) is opened
by the differential pressure between the tank
pressure and the atmosphere pressure to pre-
vent generation of the negative pressure.
q Prevention of pressure rise in tank
If the pressure rises to above a specified level
while the circuit is in operation by an increase
or decrease of oil level and the temperature
rise, sleeve (4) is operated to relieve pressure
in the hydraulic tank.
6 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Steering pump 1
Type: LPV90
P1: Pump discharge port POP: External pilot pressure input port
P1L: Pump pressure input port PS: Pump suction port
PD: Drain port
PD2: Drain plug 1. Pump body
PD6: Drain port 2. Servo valve
PEN: Control pressure pickup plug 3. Air bleeder
PLS: Load pressure input port
WA500-6 7
SEN00709-02 10 Structure, function and maintenance standard
1. Pump unit
8 WA500-6
10 Structure, function and maintenance standard SEN00709-02
1. Bearing
2. Shaft
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cover
10. Shoe retainer
11. Servo piston
12. Spring
13. Oil seal
14. Ball
WA500-6 9
SEN00709-02 10 Structure, function and maintenance standard
Function
q The pump converts the engine rotation torque
transmitted to its shaft to oil pressure and
delivers pressurized oil corresponding to the
load.
q It is possible to change the delivery by chang-
ing the swash plate angle.
Structure
q Cylinder block (6) is supported on shaft (1)
through spline (a). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (5) has a spherical hollow
and is combined with shoe (4). Piston (5) and
shoe (4) form a spherical bearing.
q Rocker cam (3) is supported on case (2) and
ball (9) and has flat surface (A). Shoe (4) is
kept pressed against the plane of rocker cam
(3) and slid circularly. Shoe (4) leads high-
pressure oil to form a static pressure bearing
and slides.
q Piston (5) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (6).
q Cylinder block (6) seals the pressurized oil to
valve plate (7) and carries out relative rotation.
q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
der block (6) is suctioned and discharged
through valve plate (7).
10 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Operation
1) Operation of pump
q Cylinder block (6) rotates together with shaft q As center line (X) of rocker cam (3) matches
(1), and shoe (4) slides on flat surface (A). the axial direction of cylinder block (6) [swash
q Rocker cam (3) slants around ball (9). As a plate angle (a) = 0], the difference between vol-
result, angle (a) between center line (X) of umes (E) and (F) inside cylinder block (6)
rocker cam (3) and the axis of cylinder block becomes 0.
(6) changes. q Suction and discharge of pressurized oil is not
q Angle (a) is called the swash plate angle. carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q Swash plate angle (a) is in proportion to the
pump delivery.
WA500-6 11
SEN00709-02 10 Structure, function and maintenance standard
2) Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Swash plate angle (a) is changed with servo
piston (11).
q Servo piston (11) reciprocates straight accord-
ing to the signal pressure of the CO valve and
LS valve.
q This straight motion is transmitted to rocker
cam (3).
q Rocker cam (3) supported with ball (9) slides
around ball (9).
12 WA500-6
10 Structure, function and maintenance standard SEN00709-02
2. Servo valve
WA500-6 13
SEN00709-02 10 Structure, function and maintenance standard
LS valve CO valve
PA: Pump pressure input PA: Pump pressure input
PE: Control piston pressure PPL: CO valve output pressure
PLS: LS pressure input T: Drain
PPL: CO valve output pressure
PPLS: LS pump pressure input
1. Nut 9. Piston
2. Plate 10. Seal
3. Plug 11. Piston
4. Spring 12. Sleeve
5. Seat 13. Spool
6. Plug 14. Seat
7. Spool 15. Retainer
8. Plug 16. Spring
14 WA500-6
10 Structure, function and maintenance standard SEN00709-02
LS valve CO valve
Function Function
q The LS valve controls the pump delivery q When the pump pressure in the hydraulic cir-
according to the stroke of the control lever, or cuit reaches the maximum level, CO (Cut Off)
the demand flow for the actuator. valve minimizes the pump swash plate angle
q The LS valve detects the demand flow for the and protects the circuit by suppressing the rise
actuator from differential pressure (dPLS) of pressure.
between control valve inlet pressure (PPLS) q The minimum pump swash plate angle given
and control valve outlet pressure (PLS) and reduces the pump suction torque to improve
controls main pump delivery (Q). ((PPLS) is fuel economy.
called the LS pump pressure, (PLS) the LS
pressure, and (dPLS) is the LS differential
pressure.)
q In other words, the pressure loss caused by
flow of oil through the opening of the control
valve spool (= LS differential pressure dPLS) is
detected, and then pump delivery (Q) is con-
trolled to keep that pressure loss constant and
supply the pump delivery according to the
demand flow for the actuator.
q Main pump discharge pressure (PA), LS pump
pressure (PPLS), and LS pressure (PLS) are
led to the LS valve. The relationship between
LS differential pressure (dPLS) and pump
delivery (Q) changes as shown below. Operation
1. Function of spring
q The spring load of spring (2) on the CO valve is
determined by the pump discharge pressure
(PA).
WA500-6 15
SEN00709-02 10 Structure, function and maintenance standard
16 WA500-6
10 Structure, function and maintenance standard SEN00709-02
WA500-6 17
SEN00709-02 10 Structure, function and maintenance standard
18 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Outline
q The pump unit is composed of the variable
capacity swash plate type piston pump, PC
valve, LS valve, and EPC valve.
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
WA500-6 19
SEN00709-02 10 Structure, function and maintenance standard
1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cover
10. Impeller
11. Servo piston
12. PC valve
20 WA500-6
10 Structure, function and maintenance standard SEN00709-02
WA500-6 21
SEN00709-02 10 Structure, function and maintenance standard
22 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Control of delivery
q If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
WA500-6 23
SEN00709-02 10 Structure, function and maintenance standard
1. LS valve
Function
q The LS (load sensing) valve detects the load of
the actuator and controls the delivery.
q This valve controls pump delivery (Q) accord-
ing to differential pressure (dPLS)
[ = (PP) – (PLS)] (called LS differential pres-
sure) between pump discharge pressure (PP)
and control valve outlet port pressure (PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
24 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Operation
q The LS valve is a 3-way selector valve, with q According to the difference in the areas on
pressure (PLS) (LS pressure) from the inlet servo piston (12), servo piston (12) moves in to
port of the control valve brought to spring the direction of minimizing the swash plate
chamber (B), and pump discharge pressure angle.
(PP) brought to port (H) of sleeve (8).
q Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump discharge pressure (self pressure) (PP)
determine the position of spool (6).
q Before starting engine, servo piston (12) is
pressed to the left. (See the figure to the right)
q If the control lever is in neutral at start of the
engine, LS pressure (PLS) is set to 0 MPa {0
kg/cm2}. (It is connected with the drain circuit
through the control valve spool.)
q Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).
q Pump pressure (PP) is present in port (J) on
the small diameter side of the piston.
WA500-6 25
SEN00709-02 10 Structure, function and maintenance standard
26 WA500-6
10 Structure, function and maintenance standard SEN00709-02
WA500-6 27
SEN00709-02 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (6) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
ship is (A0) x (PP) = (A1) x (PEN), servo piston
(12) will stop in that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q The formula (A0) : (A1) = 3 : 5 represents the
relation of pressure receiving areas across the
end of servo piston (12). And (PP) : (PEN) C 5 :
3 represents the pressure applied across the
piston when balanced.
28 WA500-6
10 Structure, function and maintenance standard SEN00709-02
2. PC valve
Function
q PC valve controls the flow to a certain rate cor-
responding to the discharge pressure irrespec-
tive of how much the control valve stroke is
increased, when pump discharge pressure
(PP1) (self pressure) and (PP2) (other pump
pressure) are high.
q Uprise in the pump discharge pressure due to
increased load during work results in reducing
the pump delivery.
q If the pump discharge pressure drops, it
increases the delivery from the pump.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and pump delivery (Q) will
become as shown in the right figure if the rela-
tion is represented as the parameter of the cur-
rent value (X) to be given to PC-EPC valve
solenoid.
q The controller continues counting the actual
engine speed.
q During low speed, command current flows
from the controller to PC-EPC valve solenoid
according to the engine speed to reduce the
pump delivery.
WA500-6 29
SEN00709-02 10 Structure, function and maintenance standard
Operation
1) When the actuator load is small and pump pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) a Other pump pressure denotes the pressure of
q Command current (X) is being sent to PC-EPC the pump situated on the opposite side.
valve solenoid (1) from the pump controller. For the front pump pressure, the other pump
q This command current (X) works on PC-EPC pressure is that of the rear pump.
valve and output the signal pressure to change And for the rear pump pressure, the other
the force of pushing piston (2). pump pressure is that of the front pump.
q Spool (3) stops at a position where the com-
bined force pressing spool (3) becomes bal-
anced between a set force of spring (4) and
pump pressure (PP1) (self pressure) and
(PP2) (other pump pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
30 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Action of spring q If port (E) and port (G) of the LS valve are con-
q The load of spring (4) at the PC valve is deter- nected, the pressure entering the large diame-
mined by the position of the swash plate. ter end of the piston from port (J) becomes
q Spring load changes as servo piston (9) makes drain pressure (PT), and servo piston (9)
spring (4) elongate or contract. moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Spring (4) extends as servo piston (9) moves
q The load of spring (4) also changes according and weakens the spring force.
to the PC-EPC valve solenoid command cur- q As the spring force is weakened, spool (3)
rent (X). moves to the right, the connection between
q Port (C) of the PC valve is connected to port port (C) and port (D) is shut off and the pump
(E) of the LS valve. discharge pressure ports (B) and (C) are con-
q Self pressure (PP1) enters port (B) and the nected.
small diameter end of servo piston (9), and q The pressure on port (C) rises and the pres-
other pump pressure (PP2) enters port (A). sure on the large diameter end of the piston
q When pump pressures (PP1) and (PP2) are also rises. Thus, the leftward move of servo
small, spool (3) will be positioned in the left piston (9) is stopped.
side. q Stop position of servo piston (9) (= pump deliv-
q Ports (C) and (D) are connected, and the pres- ery) is determined by a position where press
sure entering the LS valve becomes drain force generated by pressures (PP1) and (PP2)
pressure (PT). on spool (3) and other press force by PC-EPC
valve solenoid are balanced with the force of
spring (4).
WA500-6 31
SEN00709-02 10 Structure, function and maintenance standard
2) When the actuator load is large, and the pump discharge pressure is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the right becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP2) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to ports (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end of this to make the pump delivery the minimum.
flow, level of this pressure becomes approxi- q When servo piston (9) moves to the right,
mately half of main pump pressure (PP2). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are
low.
32 WA500-6
10 Structure, function and maintenance standard SEN00709-02
WA500-6 33
SEN00709-02 10 Structure, function and maintenance standard
3. PC-EPC valve
C: To PC valve
P: From pilot pump
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
34 WA500-6
10 Structure, function and maintenance standard SEN00709-02
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (Coil is de-energized)
q On receiving signal current (i) from the control- q When there is no signal current flowing from
ler, the EPC valve generates EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the signal current and gized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) is closed and the oil from the pilot
pump does not flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.
WA500-6 35
SEN00709-02 10 Structure, function and maintenance standard
36 WA500-6
10 Structure, function and maintenance standard SEN00709-02
WA500-6 37
SEN00709-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
38
SEN00875-01
WA500-6
WA500-6 1
SEN00875-01 10 Structure, function and maintenance standard
As for outside views and sectional views, only the 4-spool valve (with ECSS control valve) is shown.
1. Bucket valve
2. Lift arm valve
3. ECSS control valve
4. Lift arm Hi and bucket Hi valves
5. Cover 1
6. Cover 2
7. Lift arm suction valve
8. Accumulator charge valve
2 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Outside view
WA500-6 3
SEN00875-01 10 Structure, function and maintenance standard
Sectional view
(1/6)
4 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Free Installed If damaged or
x Outside
7 Check valve spring length load length load deformed,
diameter
replace spring
29.4 N 23.5 N
38.9 x 11.5 30.0 —
{3.0 kg} {2.4 kg}
WA500-6 5
SEN00875-01 10 Structure, function and maintenance standard
(2/6)
6 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Free Installed
x Outside
6 Spool return spring length load length load
diameter
393 N 315 N
54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}
417 N 333 N
7 Spool return spring 54.2 x 34.8 51.2 —
{42.5 kg} {34.0 kg}
If damaged or
351 N 280 N
8 Spool return spring 58.1 x 33.0 51.5 — deformed,
{35.8 kg} {28.6 kg}
replace spring
351 N 280 N
9 Spool return spring 51.6 x 33.0 45.0 —
{35.8 kg} {28.6 kg}
251 N 201 N
10 Spool return spring 54.9 x 24.2 52.0 —
{25.6 kg} {20.5 kg}
263 N 210 N
11 Spool return spring 66.9 x 36.1 63.5 —
{26.8 kg} {21.4 kg}
274 N 219 N
12 Spool return spring 53.2 x 22.3 33.0 —
{27.9 kg} {22.3 kg}
WA500-6 7
SEN00875-01 10 Structure, function and maintenance standard
(3/6)
8 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Free Installed If damaged or
x Outside
5 Suction valve spring length load length load deformed,
diameter
replace spring
5.5 N 4.4 N
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg}
WA500-6 9
SEN00875-01 10 Structure, function and maintenance standard
(4/6)
10 WA500-6
10 Structure, function and maintenance standard SEN00875-01
1. Unload valve
Bucket valve
2. EPC valve (Tilt)
3. Load check valve (Dump)
4. Load check valve (Tilt)
5. EPC valve (Dump)
6. Suction safety valve (Tilt)
7. Spool
8. Suction safety valve (Dump)
WA500-6 11
SEN00875-01 10 Structure, function and maintenance standard
(5/6)
12 WA500-6
10 Structure, function and maintenance standard SEN00875-01
ECSS valve
9. Spool
10. EPC valve
11. Accumulator charge valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Free Installed
x Outside
12 Check valve spring length load length load
diameter
If damaged or
5.9 N 4.72 N
41.5 x 8.5 31.5 — deformed,
{0.6 kg} {0.48 kg}
replace spring
19.6 N 15.7 N
13 Valve spring 19.2 x 7.2 16.1 —
{2.0 kg} {1.6 kg}
3.04 N 2.43 N
14 Suction valve spring 62.5 x 20.0 39.0 —
{0.31 kg} {0.25 kg}
WA500-6 13
SEN00875-01 10 Structure, function and maintenance standard
(6/6)
14 WA500-6
10 Structure, function and maintenance standard SEN00875-01
WA500-6 15
SEN00875-01 10 Structure, function and maintenance standard
CLSS 1
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with a variable capacity
tem, and has the following features. piston pump, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
16 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Basic principle
1. Pump swash plate angle control q The pump swash plate angle shifts toward the
q The pump swash plate angle (pump delivery) maximum position if LS differential pressure
is so controlled that the LS differential pressure (EPLS) is lower than the set pressure of the
(EPLS), which is the differential pressure LS valve (when the actuator load pressure is
between the pump discharge pressure (PPS) high).
and LS pressure (PLS) (the actuator load pres- q If it becomes higher than the set pressure
sure) at the control valve outlet, will be con- (when the actuator load pressure is low), the
stant. pump swash plate angle shifts toward the mini-
q [LS differential pressure (EPLS) = Pump dis- mum position.
charge pressure (PPS) – LS pressure (PLS)]
WA500-6 17
SEN00875-01 10 Structure, function and maintenance standard
q The valve (pressure compensation valve) to q This prevents the bucket from becoming inop-
balance the load is installed to the lift arm head erable because of excessive oil flow to the lift
outlet side of the control valve. arm head due to the lowering of lift arm under
q When actuators are operated simultaneously, its own weight and compound operation of the
the pressure difference (EP) between the bucket.
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve.
18 WA500-6
10 Structure, function and maintenance standard SEN00875-01
WA500-6 19
SEN00875-01 10 Structure, function and maintenance standard
1. Bucket valve
2. Lift arm valve
3. ECSS valve
4. Lift arm Hi valve
5. Bucket Hi valve
6. Bucket spool
7. Lift arm spool
8. ECSS spool
9. Lift arm spool
10. Bucket spool
11. Pressure compensation valve
12. Suction valve
13. Load check valve
14. Accumulator charge valve
15. Main relief valve
Set pressure:
34.3 ± 0.5 MPa {350 ± 5 kg/cm2}
16. Unload valve
Cracking pressure:
1.96 ± 0.2 MPa {20 ± 2 kg/cm2}
17. Suction safety valve
Set pressure:
36.2 ± 0.5 MPa {370 ± 5 kg/cm2}
20 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Function Operation
q High load pressure is generated during inde- q Actuator circuit pressure (B) becomes higher
pendent operation of the lift arm and com- than pump discharge pressure (PPS) and LS
pound operation with the bucket. pressure (PLS).
q When the lift arm load pressure becomes q Shuttle valve (3) of the pressure compensation
higher than the bucket, the pressure compen- valve moves to the right.
sation valve operates as a load check valve to q Actuator circuit pressure (B) and spring cham-
prevent reverse oil flow in the circuit. ber (C) are connected.
q Accordingly, piston (4) is pressed by spring (5)
to the left.
q Also valve (2) is pressed by piston (4) to the
left and pump outlet circuit (A) is closed. This
prevents reverse flow of oil from actuator cir-
cuit (B) to pump outlet circuit (A).
WA500-6 21
SEN00875-01 10 Structure, function and maintenance standard
Function Operation
q If the load pressure is lower than the bucket q If the load pressure on the bucket side rises
and the flow rate starts increasing during com- during compound operation, the flow rate of
pound operation, the pressure compensation actuator circuit pressure (B) starts to increase.
valve compensates the pressure. q As LS pressure (PLS) rises on the bucket side,
q On the bucket side, the load pressure is higher shuttle valve (3) of the pressure compensation
and the flow rate starts to decrease. valve is pressed to the left.
q Hydraulic oil flows through the internal pas-
sage of piston (4) to spring chamber (C).
q Piston (4) and valve (2) are pressed to the left
and the outlet side of pump circuit (PPS) is cut
off.
q Outlet pressure (A) (spool meter-in down-
stream pressure) becomes equal to the bucket
outlet pressure.
q Pump pressure (PPS) (spool meter-in
upstream pressure) becomes equal for all
actuators.
q Pump pressure (PPS) and outlet pressure (A)
becomes equal for all spools.
q Pump flow rate is distributed in proportion to
the opening area of respective spools.
22 WA500-6
10 Structure, function and maintenance standard SEN00875-01
1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston
Function
q Shuttle valve (3) is pressed to the right by port
(B) pressure and ports (B) and (D) are cut off.
q Holding pressure of port (B) is led to spring
chamber (C) and piston (4) is pressed to the
left to prevent it from being separated from
valve (2).
WA500-6 23
SEN00875-01 10 Structure, function and maintenance standard
Function
q The state of division changes according to the
area ratio of pressure compensation portions
(A1) and (A2). Area ratio = (A2)/(A1)
q Since the area ratio is less than 1, spool meter-
in downstream pressure < maximum load
pressure, and the oil flow is divided greater
than by the area ratio of the opening.
24 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Supply of LS pressure
(LS shuttle valve)
Function Operation
q The LS pressure (PLS) means the actuator q If main spool (2) is operated, pump discharge
load pressure on the outlet side of the control pressure (PPS) flows to actuator circuit (B).
valve. q Pump discharge pressure (PPS) is led through
q Pressure compensation valve (3) upstream orifice (a) of main spool (2) to LS circuit (PLS).
pressure (spool meter-in downstream pres- q When actuator circuit (B) rises to necessary
sure) is led through main spool (2) to LS shut- pressure level, pump discharge pressure
tle valve (7). (PPS) rises.
q Connected to actuator port (B) through valve q Check valve (5) in main spool (2) opens and
(4), and makes LS pressure C actuator load the high pressure in LS circuit (PLS) flows out
pressure. to actuator circuit (B).
q Orifice (a) inside main spool (2) has a small q Pressure in LS circuit (PLS) becomes approxi-
diameter concurrently serving as a throttle. mately equal to that of actuator circuit pressure
(B).
WA500-6 25
SEN00875-01 10 Structure, function and maintenance standard
LS bypass valve 1
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass valve
6. LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Bypass flow from LS bypass valve (5) causes
a pressure loss to be generated due to the cir-
cuit resistance between throttle (c) of main
spool (2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
26 WA500-6
10 Structure, function and maintenance standard SEN00875-01
WA500-6 27
SEN00875-01 10 Structure, function and maintenance standard
28 WA500-6
10 Structure, function and maintenance standard SEN00875-01
WA500-6 29
SEN00875-01 10 Structure, function and maintenance standard
Function
q Discharge pressure (P) of the hydraulic pump
is reduced and the oil is supplied to the ECSS
accumulator.
Operation
q Poppet (2) is pressed by spring (3) against the
seat and the line from port (P1) to port (T) is
closed.
q Poppet (6) is pressed to the left and the line
from port (P1) to port (PR) is closed.
q Poppet (6) is moved to the right by pressure
(P1) and the line from (P1) to (PR) is opened. If
(P1) < (PR), poppet (6) is pressed to the left by
spring (7) and the line from (P1) to (PR) is
closed.
30 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Operation
q If pressure (P) rises above the set pressure,
poppet (3) opens and the hydraulic oil flows
through port (P1), hole (a) in spool (5), opening
of poppet (2), and tank port (T).
q Accordingly, differential pressure is made
before and after hole (a) in spool (5) and spool
(5) moves to close the opening between ports
(P) and (P1). Pressure (P) is reduced to a cer-
tain pressure (the set pressure) by the open
area at this time and supplied as pressure
(P1).
WA500-6 31
SEN00875-01 10 Structure, function and maintenance standard
Operation
q After engine is stopped, chamber (A) in the
bladder is compressed by oil pressure in
chamber (B).
q When work equipment EPC solenoid is tripped
by operating the work equipment EPC lever,
pressure inside nitrogen gas chamber (A)
expands the bladder, and the oil in chamber
(B) operates the work equipment valve as the
pilot pressure.
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen gas
Amount of gas: 500 cc
Max. operating pressure: 3.92 MPa {40 kg/cm2}
Min. operating pressure: 0 MPa {0 kg/cm2}
Function
q Accumulator is installed between the charge
valve and work equipment valve. In the case
the engine is stopped with the lift arm lifted up,
compressed nitrogen gas pressure in the accu-
mulator feeds the pilot oil pressure to the work
equipment valve for operation. Thus the lift
arm and bucket are enabled to descend under
own weight.
32 WA500-6
10 Structure, function and maintenance standard SEN00875-01
WA500-6 33
SEN00875-01 10 Structure, function and maintenance standard
34 WA500-6
10 Structure, function and maintenance standard SEN00875-01
Function
q When lever (1) is operated, rod (20) moves up
and down and rotates potentiometer (10)
according to the operating distance of the
lever.
q The operating angle (stroke) of the control
lever is sensed with the potentiometer and out-
put as a signal voltage to the controller.
q A potentiometer is installed, and it outputs 2
signal voltages which are opposite to each
other as shown in “Lever stroke - voltage”
characteristics.
Operation
WA500-6 35
SEN00875-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
36
SEN00710-02
WA500-6
WA500-6 1
SEN00710-02 10 Structure, function and maintenance standard
Work equipment 1
Work equipment linkage 1
2 WA500-6
10 Structure, function and maintenance standard SEN00710-02
WA500-6 3
SEN00710-02 10 Structure, function and maintenance standard
4 WA500-6
10 Structure, function and maintenance standard SEN00710-02
Unit: mm
No. Check item Criteria Remedy
Standard Standard
Tolerance Clear-
size clear-
Clearance between bushing and pin at each ance limit
1 Shaft Hole ance
end of bucket link
–0.036 +0.307 0.256 –
120 1.0
–0.090 +0.220 0.397
Clearance between bushing and pin con- –0.036 +0.307 0.256 –
2 120 1.0
necting lift arm and bucket –0.090 +0.220 0.397
Clearance between bushing and pin con- –0.043 +0.395 0.338 –
3 140 1.0
necting lift arm and frame –0.106 +0.295 0.501 Replace
Clearance between bushing and pin con- –0.043 +0.395 0.338 – [Replace if pin
4 125 1.0 has scuff mark]
necting bucket cylinder bottom and frame –0.106 +0.295 0.501
Clearance between bushing and pin con- –0.043 +0.395 0.338 –
5 125 1.0
necting bucket cylinder rod and bell crank –0.106 +0.295 0.501
Clearance between bushing and pin con- –0.043 +0.395 0.338 –
6 160 1.0
necting bell crank and lift arm –0.106 +0.295 0.501
Clearance between bushing and pin con- –0.036 +0.307 0.256 –
7 120 1.0
necting lift cylinder bottom and frame –0.090 +0.220 0.397
Clearance between bushing and pin con- –0.036 +0.307 0.256 –
8 120 1.0
necting lift cylinder rod and lift arm –0.090 +0.220 0.397
Standard
Boss to boss clearance
Connecting part of bucket cylinder and Width of hinge
9 width (Clearance of
frame a+b)
153 150 3.0
10 Connecting part of lift arm and frame 183 180 3.0 Adjust
11 Connecting part of lift arm and bucket 183 180 3.0 [Insert shims to
12 Connection of bucket link and bucket 183 180 3.0 both sides so that
clearance will be
Connecting part of bell crank and bucket below 1.5 mm on
13 183 180 3.0
link each side]
14 Connecting part of lift cylinder and frame 153 150 3.0
15 Connecting part of bell crank and lift arm 316 313 3.0
Connecting part of bucket cylinder and bell
16 155 150 5.0
crank
17 Connecting part of lift arm and lift cylinder 153 150 3.0
WA500-6 5
SEN00710-02 10 Structure, function and maintenance standard
Bucket 1
3
Bucket 5.6 m (with Bolt-on cutting edge)
1. Bucket
2. Bolt-on cutting edge (BOC)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
3 Wear on edge Turn over or replace
38 15
6 WA500-6
10 Structure, function and maintenance standard SEN00710-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Wear on bucket teeth Replace
38 23
Clearance in bucket tooth mount-
2 Max. 0.5 (Clearance between edge) Adjust or replace
ing parts
3 Wear on segment edge 38 15 Turn over or replace
WA500-6 7
SEN00710-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
1 Clearance of bucket positioner switch 3–5
Clearance of lift arm position detection Adjust
2 0.5 – 1
switch
8 WA500-6
10 Structure, function and maintenance standard SEN00710-02
WA500-6 9
SEN00710-02 10 Structure, function and maintenance standard
10 WA500-6
10 Structure, function and maintenance standard SEN00710-02
Bucket cylinder
Unit: mm
No. Check item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance
1 between piston -0.036 +0.263 0.084 - Replace bushing
Lift 120 0.653
rod and bushing -0.090 +0.048 0.353
-0.036 +0.263 0.084 -
Bucket 120 0.653
-0.090 +0.048 0.353
Tightening torque Lift 529.7 ± 78.5 Nm {54.0 ± 8.0 kgm}
2
of cylinder head Bucket 892 ± 137 Nm {91.0 ± 14 kgm}
Tightening torque Lift 294 ± 29.4 Nm {30 ± 3.0 kgm}
3 Retighten
of cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque Lift 58.9 - 73.6 Nm {6.0 - 7.5 kgm}
4 of cylinder piston
lock screw Bucket 58.9 - 73.6 Nm {6.0 - 7.5 kgm}
WA500-6 11
SEN00710-02
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
12
SEN00711-01
WHEEL LOADER
1SHOP MANUAL
2SHOP MANUAL
WA500-6
WA500-6 1
SEN00711-01 10 Structure, function and maintenance standard
1. Front glass
2. Front wiper
3. Door
4. Rear wiper
2 WA500-6
10 Structure, function and maintenance standard SEN00711-01
WA500-6 3
SEN00711-01 10 Structure, function and maintenance standard
Air conditioner 1
Air conditioner piping diagram
4 WA500-6
10 Structure, function and maintenance standard SEN00711-01
WA500-6 5
SEN00711-01 10 Structure, function and maintenance standard
6 WA500-6
10 Structure, function and maintenance standard SEN00711-01
Condenser
1. Fin Function
2. Tube q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
A: Refrigerant gas outlet port compressor.
B: Refrigerant gas inlet port
a If the fin crushes or is clogged with dusts, heat
exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
2
Total heat dissipation surface (m ) 6.55
2
Max. pressure used (MPa {kg/cm }) 3.6 {36}
WA500-6 7
SEN00711-01 10 Structure, function and maintenance standard
Compressor
1. Case Function
2. Clutch q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
A: Suction service valve tor to high-pressure, high-temperature misty
B: Discharge service valve refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders – Bore x Stroke
5 – 35 x 28.6
(mm)
Piston capacity
138
(cc/rev)
Allowable maximum speed
4,000
(rpm)
8 WA500-6
10 Structure, function and maintenance standard SEN00711-01
Receiver 1
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
WA500-6 9
SEN00711-01 10 Structure, function and maintenance standard
Display unit
Display Display
No. Displayed items Display range Display method Remarks
category color
Spurting out See above All segments below applicable level come on
1
temperature figure (8-step display)
Gauges
Air blasting See above All segments below applicable level come on
2
volume figure (4-step display)
Circulation of When circulating The display indicates which is currently taking Liquid
internal air and internal air and place – internal air circulation or external air Black
3 crystal
introduction of introducing introduction – responding to the operation of
Pilot external air external air the internal/external air changeover switch.
When air condi-
Turns “ON” air conditioner switch, this lamp
4 Air conditioner tioner switch is
lights up.
turned “ON”
Switch block
No. Type Function Operation
It is used for selecting the internal air circulation or external air
Internal air circulation
Internal/external air introduction
5 I O
changeover switch (The pilot indication on the display unit varies depending on the
External air introduction
given setting.)
It turns on or off the cooling and the dehumidifying heating func-
6 Air conditioner switch OFF i o ON
tion.
This switch turns on or off the main power of the air conditioner.
ON: Display unit indicates the setting being specified when
7 Main power switch OFF i o ON
power was turned “OFF”.
OFF: Turns off the display unit and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO i o HI
(Adjusted in 4 steps [LO, M1, M2, HI])
Low temperature
Temperature adjusting It is used to control spurting out temperature.
9 I O
switch (8-step adjustment)
High temperature
10 WA500-6
10 Structure, function and maintenance standard SEN00711-01
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
WA500-6 11
SEN00711-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
12
SEN00712-04
WA500-6
WA500-6 1
SEN00712-04 10 Structure, function and maintenance standard
2 WA500-6
10 Structure, function and maintenance standard SEN00712-04
q The service mode function is used for the ease 9. Function of selecting optional device
of troubleshooting for the controllers on the Information of the controller to be used and
network (including the machine monitor itself). optional device are selected.
The major functions used in the service mode
are as follows. 10. Input of machine serial number (No.)
Enter the machine serial number to specify the
1. Display of electrical system failure history machine.
The electrical system failures of each controller
saved in the machine monitor are displayed. 11. Model selection function
The information of those failures is deleted Enter the information of applicable model.
with this function, too.
12. Initialize
2. Display of mechanical system failure history This function is used to set the machine moni-
The mechanical system failures of each con- tor to the state set when delivered.
troller saved in the machine monitor are dis-
played.
3. Real-time monitor
The input and output values recognized by
each controller on the network are displayed in
real time.
4. Reduced-cylinder mode
This function is used to stop fuel injection by
cylinder and specify the cylinder having defec-
tive fuel by shutting off fuel injected from the
fuel injector.
5. No injection cranking
This function is used when lubricating the
engine with the engine stopped when restart-
ing it after a long time of non-operation.
6. Adjustment function
The installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
are corrected and adjusted, and control char-
acteristic data is changed upon request of the
user.
7. Maintenance monitor
The filter and oi l replacement period is
changed and its function is stopped.
WA500-6 3
SEN00712-04 10 Structure, function and maintenance standard
4 WA500-6
10 Structure, function and maintenance standard SEN00712-04
Load meter
WA500-6 5
SEN00712-04 10 Structure, function and maintenance standard
Sensing
6 WA500-6
10 Structure, function and maintenance standard SEN00712-04
WA500-6 7
SEN00712-04 10 Structure, function and maintenance standard
8 WA500-6
10 Structure, function and maintenance standard SEN00712-04
WA500-6 9
SEN00712-04 10 Structure, function and maintenance standard
Machine monitor 1
1. Torque converter oil temperature gauge 28. Battery charge circuit caution lamp
2. Torque converter oil temperature caution lamp 29. Steering oil pressure caution lamp
3. Engine coolant temperature gauge 30. Emergency steering pilot lamp
4. Engine coolant temperature caution lamp 31. Output mode pilot lamp (Power mode)
5. Speedometer or engine tachometer 32. Preheater pilot lamp
6. Display of the unit of speedometer or engine 33. Semi auto digging pilot lamp
tachometer 34. Auto-grease pilot lamp (Not used)
7. Turn signal pilot lamp (Left) 35. Joystick pilot lamp (If equipped)
8. Head lamp high beam pilot lamp 36. Directional selector pilot lamp (Not used)
9. Turn signal pilot lamp (Right) 37. ECSS pilot lamp (Not used)
10. Hydraulic oil temperature gauge 38. Economy operation indicator lamp
11. Hydraulic oil temperature caution lamp 39. Shift position pilot lamp (Forward/reverse)
12. Fuel level gauge 40. Shift position pilot lamp (Gear speed)
13. Fuel level caution lamp 41. Shift indicator
14. Central warning lamp 42. Auto-shift pilot lamp
15. Brake oil pressure caution lamp 43. Lockup pilot lamp
16. Engine oil pressure caution lamp 44. Shift hold pilot lamp
17. Water separator caution lamp (Not used) 45. Display of bucket loading (If equipped)
18. Engine oil level caution lamp 46. Addition mode: Total loading display/Reduction
19. Radiator coolant level caution lamp mode: Display of level (If equipped)
20. Parking brake pilot lamp 47. Working object display (If equipped)
21. Air cleaner clogging caution lamp 48. Addition/reduction mode display (If equipped)
22. Transmission oil filter clogging caution lamp 49. Character display
23. Axle oil temperature caution lamp
24. Modulation clutch temperature caution lamp
(Not used)
25. Cooling fan reverse rotation pilot lamp
26. Maintenance caution lamp
27. Battery electrolyte level caution lamp
(If equipped)
10 WA500-6
10 Structure, function and maintenance standard SEN00712-04
WA500-6 11
SEN00712-04 10 Structure, function and maintenance standard
Display color
(SEC)
Category
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Lights when error (E03, E02)
Central warning lamp
Red
When error is made E E E E E E E E E
the same time displays mes-
sage.
14 Central warning lamp LED
Other than above, see “Oper-
ating condition – Central
— — — — — — — —
warning lamp” column of rele-
vant items.
For night Back light:
White
Back light
Back
light
Remarks
Remarks
Note 1)
Central
Main part
warning Buzzer Message
(*1)
lamp
Overrun notice Q w w (flashing) —
Overrun Q w w (flashing) Overrun prevention
(*1) When the engine speed is displayed on the center LCD, the display flashes.
When the travel speed is displayed, it is switched to the engine speed and
the display flashes.
12 WA500-6
10 Structure, function and maintenance standard SEN00712-04
Display color
Stopped ning
(SEC)
Category
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Torque converter Pointer:
1 — — — — — — — — —
oil temperature Movement MAX position: 135°C
Red zone start point: 120°C
Red
abnormality is detected 10 1 — Q — — Q — 1/4 of full scale: 80°C
(See figures
(DGT1KX is not generated)] Min. position 50°C
below.)
When sensor is grounded: Max.
Torque converter Monitor of gauge
Indicator: Alarm: Min. 130°C and [No
2 oil temperature When sensor is disconnected or
Red
LED abnormality is detected 10 1 w Q Q w Q Q
caution lamp hot shorted: Min. of gauge
(DGT1KX is not generated)]
When abnormality is
Red
20 5 — — — — — — b@CENS does not display character message.
detected
Red
3 — Q — — — Q — —
(CA144 and CA145 are not
generated)]
MAX position: 135°C
Operation of gauges and meters
Red
Engine coolant
Indicator: Alarm: Min. 105°C w Q Q w Q Q monitor below.) 1/4 of full scale: 65°C
4 temperature cau- Min. position: 50°C
LED
tion lamp
When abnormality is
— — — — — —
detected
When abnormality is
— — — — — —
detected
Hydraulic oil tem- Pointer: Max. position: 125°C
10 — — — — — — — — —
perature Movement Red zone start point: 100°C
Level: 85°C (green graduations
DGH2KX B@HANS
DGH2KX B@HANS
WA500-6 13
SEN00712-04 10 Structure, function and maintenance standard
Display color
(SEC) Stopped running
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
[When F is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
[When R is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
When F is selected 0 0 — Q — — Q — Green
When N is selected 0 0 — Q — — Q — Green
39 Shift position When R is selected 0 0 — Q — — Q — Green Monitor
LED
40 pilot lamp TM
When 4th gear speed is selected 0 0 — Q — — Q — Green
When 3rd gear speed is selected 0 0 — Q — — Q — Green
When 2nd gear speed is selected 0 0 — Q — — Q — Green
When 1st gear speed is selected 0 0 — Q — — Q — Green
Actual gear speed
B@BAZG
B@BCZK
14 WA500-6
10 Structure, function and maintenance standard SEN00712-04
Display color
(SEC) Stopped running
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
When parking brake is applied (OPEN) — Q — — Q — Red
When parking brake is not applied
Parking — — — — — — —
(CLOSED)
20 brake pilot LED Monitor
lamp Other than when parking brake is applied
and gear shift lever is at “N” position, and 0 0 A Q Q Red
during starting engine
Normal (CLOSED) — — — — — — —
Air cleaner
AA1ANX
21 clogging cau- LED Monitor
Sensor detects clogging (OPEN) 2 1 — — — — Q — Red
Others
tion lamp
Normal (CLOSED) — — — — — — —
15BONX
Clogging (OPEN) and torque converter
Transmis- 2 1 — — — — Q — Red
oil temperature > 50°C If abnormality is detected while engine is
sion oil filter
22 LED Monitor stopped, alarm is continued even after
clogging cau-
DHT2L6
engine is started.
tion lamp OFF
When abnormality is detected 3 — — — — — — —
— — — — — — Red
Other than below — — — — — — — — —
Temperature increase (Min. 120°C)
5 5 — Q — — — Q — — Red
(notice alarm)
Temperature increase (1 or 2 below)
1. Oil temperature is above 130°C for 5
seconds.
B@C7NS
B@C7NS
2. When travel speed is above 35 km/h
while brake oil temperature, 125°C and 5 5 w Q Q w Q Q Red
Axle oil tem- above, is detected continuously for 5 sec-
23 perature cau- LED onds. It is released when oil temperature, Monitor
tion lamp 125°C and below, is detected continu-
ously for 5 seconds.
DGR2KX DGR2KA
DGR2KX DGR2KA
As indicated at right
B@GAZK
Battery elec-
27 trolyte level LED Sensors: Less than 2 V 10 1 — Q — — — Red Monitor
caution lamp
Battery age.
(Hysteresis on the right figure), no start-
charge cir- 30 1 — — — w Q Q Red
28 LED ing motor C signal input, and during run- Monitor
cuit caution ning of engine
lamp
AB00L6
Not in operation — — — — — — — — — —
Steering oil In operation (CN3-3 = OPEN) — — Q — — Q — Red Implemented only when “Emergency steer-
DDE5MA
DDE5MA
WA500-6 15
SEN00712-04 10 Structure, function and maintenance standard
Display color
(SEC) Stopped running
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Normal operation
Emergency [Operation of divider
1 1 — Q — — Q — Green
30 steering pilot LED (= Below S/T pressure CN3-3=OPEN)] Monitor
lamp and [Travel speed, min. 1 km/h]
Holds in position — — — — — —
Output mode Power mode = P 0 0 — Q — — Q — Green
pilot lamp Trans-
31 LED Selection of power mode is displayed.
(power Power mode = Other than P — — — — — — — — mission
mode)
Preheating Other than below — — — — — — —
32 LED Engine
pilot lamp In preheating (with signal) 0 0 — Q — — Q — Red
Semi auto When auto digging switch is OFF — — — — — — —
33 digging pilot LED When auto digging switch is ON 0 0 — Q — — Q — Green BBC
lamp When error is made in communication — — — — — — —
Option is not applied — — — — — — — — —
Operation of steering wheel — — — — — — — — — Monitor
Others
Operation of joystick system only when Trans- CAN input signal from transmission con-
0 0 — Q — — — Q — — Green
joystick optional setting is made. mission troller
Joystick lever neutral lock (Output from CAN input signal from work equipment
0 0 A w Q — A w Q — Green BBC
work equipment controller) controller
Operation of FR prohibition function dur-
Trans- CAN input signal from transmission con-
Joystick pilot ing locking of joystick steering only when 0 0 A w Q — A w Q — Green
35 LED mission troller
lamp joystick optional setting is made.
Key ON and transmission controller in
CAN input signal from work equipment
other than N (joystick) only when joystick 0 0 A w Q — A w Q — Green BBC
controller
optional setting is made.
FNR lever priority caution (only machine
equipped with steering wheel and joy- Trans- CAN input signal from transmission con-
1 0 A w Q A w Q — Green
stick) only when joystick optional setting mission troller
is made.
When error is made in communication — — — — — — —
Economy Economy mode 0 0 — Q — — Q — Green
operation Trans-
38 LED
indicator Other than above 0 0 — — — — — — — mission
lamp
Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of operation > Check of acceptance of operation.
16 WA500-6
10 Structure, function and maintenance standard SEN00712-04
Using the character display function, you can change the display and settings on the machine monitor.
For usage of functions for the operator, see the Operation and Maintenance Manual.
The operator can operate the part “Operator disclosure function” below.
(*1) Once you pass on the ID input screen, you can directly move to the function selection screen without
displaying this screen until the starting switch is turned OFF.
WA500-6 17
SEN00712-04 10 Structure, function and maintenance standard
18 WA500-6
10 Structure, function and maintenance standard SEN00712-04
Example of a failure code screen (Simultaneously occurring errors: D191KA, B@BCZK, CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the “>” switch in the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
WA500-6 19
SEN00712-04 10 Structure, function and maintenance standard
(*1) This display is not available when the load meter function was turned off through OPT selection of Ser-
vice Mode.
(*2) This menu is not available when the function to display the travel speed/rpm on the character display is
turned OFF through the option selection of service mode.
20 WA500-6
10 Structure, function and maintenance standard SEN00712-04
I D to e nt er th e s er v i c e mo de is
“6491”.
Remarks: If the starting switch is
turned OFF in the service mode, the
normal service meter screen or alarm
screen is returned at the next starting
switch ON.
WA500-6 21
SEN00712-04 10 Structure, function and maintenance standard
[ ] field displays number of the failure history [ ] field displays number of the failure history
currently recorded (up to 20 cases). currently recorded (up to 20 cases).
Outline Outline
This function is used to check the electrical system This function is used to check the mechanical sys-
failure history of each controller saved in the tem failure history of each controller saved in the
machine monitor. For the failure codes displayed in machine monitor. For the failure codes displayed in
the electrical system failure history, see “Trouble- the mechanical system failure history, see “Trouble-
shooting”. After each failure is repaired and the nor- shooting”.
mal operation is confirmed, delete the failure
history.
22 WA500-6
10 Structure, function and maintenance standard SEN00712-04
Outline Outline
This function is used to check the input and output This function is used when lubricating the engine
signals, etc. recognized by each controller on the with the engine stopped when restarting it after a
network. long time of non-operation.
For the starting method of engine using this func-
4) CYLINDER CUT-OUT screen tion, see “Testing and adjusting: No injection crank-
ing operation of engine”.
6) TUNING screen
Outline
This function is used to stop fuel injection by cylin-
der and specify the cylinder having defective com-
bustion by shutting off fuel injected from the fuel Outline
injector. The installation errors and manufacturing disper-
For the method of checking using this function, see sion of the sensors, solenoid valves, etc. are cor-
“Testing and adjusting: Operating engine in reduce rected and adjusted, and control characteristic data
cylinder mode”. is changed upon request of the user. Use this func-
tion if you have changed or added sensors, valves
or controllers. For adjustment using this function,
see “Testing and adjusting: Adjustment performed
on the monitor”.
WA500-6 23
SEN00712-04 10 Structure, function and maintenance standard
Outline Outline
This function is explained in “Operation and Mainte- With this function, you can display installation of an
nance Manual, Operation, Character display, Dis- optional device and change the setting of that
play of replacement periods of filters and oils”. The device. Use this function after any optional device
set replacement periods of a filter and oil are is installed or removed. For the method of setting
changed and their functions are stopped. and changing this function, see “Testing and adjust-
ing: Adjustment performed on the monitor”.
8) OPERATION INFO screen
10) MACHINE No. SET screen
Outline
Fuel consumption per operating hours is displayed. Outline
This function is used to display and set the machine
serial Nos. to control the machines.
24 WA500-6
10 Structure, function and maintenance standard SEN00712-04
Outline
This function is used to display or select the
machine model.
Outline
This function is used only in the factory. Do not use
it.
WA500-6 25
SEN00712-04 10 Structure, function and maintenance standard
1) Display of electrical system failure history and selection of clearing entirely the electrical system failure
history
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the older ones to the newer ones.
After the oldest saved item, the “Electrical system failure history all clear selected” screen is displayed.
Pressing the t switch changes the screen to the “Electrical system failure history selected” screen.
Pressing the U switch changes the screen to the “Electrical system failure history individual cleared” screen
or the “Electrical system failure history all cleared” screen.
26 WA500-6
10 Structure, function and maintenance standard SEN00712-04
3) Display of electrical system failure history and the electrical system failure history all clear selected (2nd
layer)
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the older ones to the newer ones.
Pressing the t switch changes the screen to the “Display electrical system failure history” screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
q If there is only 1 history, the current screen does not change to the “Electrical system failure history all
clear” screen (Only the “Electrical system failure history individual clear” screen is displayed).
4) Electrical system failure history individual clear and Electrical system failure history all clear (3rd layer)
Select “YES” or “NO” with the < or > switch.
The cursor “_” blinks on the selected item. If “YES” is selected and the t switch is pressed, clearing is exe-
cuted. If “NO” is selected and the t switch is pressed, clearing is cancelled and the display changes as
shown below.
q If clearing is cancelled (NO), the current screen returns to the “Display electrical system failure history”
screen of the corresponding failure.
(Returns to the screen before the “Electrical system failure history individual clear” (Electrical system
failure history all clear) screen).)
q If clearing is executed (YES), the current screen returns to the “Display electrical system failure history”
screen of the corresponding next failure.
After all the failure histories are cleared, the current screen returns to the “Select electrical system fail-
ure history” screen.
By default, the cursor is on NO (cancel) to prevent resetting by an error.
You cannot delete a failure which has not been reset. At this time, the operation cancel peep (for 1 sec) is
heard.
If any failure history is cleared, the operation acceptance peeps (“ON” for 0.1 sec, “OFF” for 0.1 sec, “ON” for
0.1 sec) are heard.
When clearing of all the histories is selected, if there is any history to be cleared, clearing is assumed to be
completed.
WA500-6 27
SEN00712-04 10 Structure, function and maintenance standard
28 WA500-6
10 Structure, function and maintenance standard SEN00712-04
WA500-6 29
SEN00712-04 10 Structure, function and maintenance standard
The real-time monitor function displays the information saved in the controllers mounted on the machine in
real time.
This function is used for testing, adjusting, or troubleshooting the machine.
This function classifies the items and data by the controllers having them, and then displays the results. It
has 2 display modes of the normal display mode and the 2-item display mode for displaying 2 data simulta-
neously.
Operating procedure
1. Hold the t switch and < switch simultaneously for at least 5 seconds to change the screen to the ID
inputting screen.
2. Input the ID with the < and > switches, and then press the U switch to enter the screen for the service
person.
3. Using the < and > switches, display “Real-time monitor selection” screen, and then press the U switch.
30 WA500-6
10 Structure, function and maintenance standard SEN00712-04
WA500-6 31
SEN00712-04 10 Structure, function and maintenance standard
5. Press the U switch while each selection In display of 2 items mode, input the ID of infor-
screen is displayed, and then the “Display 1 mation to display 2 items simultaneously.
item” screen or “Select 2 items display infor- The ID displayed is the same as the ID number
mation” screen appears. displayed on the “Display 1 item” screen.
How to input ID
“00000” is displayed during screen transition.
Input a value between 0 and 9 at the cursor (_)
position.
First, the cursor appears at the highest-order
digit. Each time the > or < switch is pressed,
the digit changes by 1 between 0 and 9.
Select a desired digit and press the U switch.
The cursor moves to the 2nd position. Select
the digits for the all positions in the same man-
ner as the previous steps.
Input a value at the lowest-order digit and
press the U switch to move to the screen to
select the display of 2nd item.
If you press the t switch during the process-
ing, the screen returns to the “Select 2 items
display information” screen.
32 WA500-6
10 Structure, function and maintenance standard SEN00712-04
WA500-6 33
SEN00712-04 10 Structure, function and maintenance standard
34 WA500-6
10 Structure, function and maintenance standard SEN00712-04
No. Item ID No. Display of item Contents of display data Display contents in normal operation Remarks
Load meter calculated weight Only when optional setting is made
26 Classified weight 40800 MES LOAD Load weight [t]
is displayed in load meter
27 Position of rotary switch 30802 SW1, SW2, SW3 — — Not used.
28 Position of DIP switch 30904 SW5-1, SW5-2 — — Not used.
29 Position of DIP switch 30905 SW5-3, SW5-4 — — Not used.
30 Position of DIP switch 30906 SW6-1, SW6-2 — — Not used.
31 Position of DIP switch 30907 SW6-3. SW6-4 — — Not used.
10000000 (Head lamp = on) D-IN-0: Head lamp
00000000 (Not used) D-IN-1: Not used
00100000 (Starting motor C = on) D-IN-2: Starting motor C
The state of input signal is 00000000 (Not used) D-IN-3: Not used
32 Input signal D_IN_0-7 40900 D-IN--0------7
displayed 00000000 (Not used) D-IN-4: Not used
00000000 (Not used) D-IN-5: Not used
00000000 (Not used) D-IN-6: Not used
00000000 (Not used) D-IN-7: Not used
D-IN-8: Not used
D-IN-9: Not used
00000000 (Not used) D-IN-10: Load meter material selec-
00000000 (Not used) tor SW input
00100000 (Load meter material selector SW = (Only when optional setting is made
on) in load meter)
The state of input signal is 00010000 (Load meter addition/reduction selec- D-IN-11: Load meter addition/reduc-
33 Input signal D_IN_8-15 40901 D-IN- 8-----15
displayed tor SW = on) tion selector SW input
00001000 (Right winker on) (Only when optional setting is made
00000100 (Left winker on) in load meter)
00000010 (Monitor mode SW (U) = on) D-IN-12: Winker right
00000001 (Monitor mode SW (t) = on) D-IN-13: Winker left
D-IN-14: Monitor mode SW (U)
D-IN-15: Monitor mode SW (t)
10000000 (Front brake oil pressure SW = on = D-IN-16: Brake oil pressure (Front)
low level) D-IN-17: Brake oil pressure (Rear)
01000000 (Rear brake oil pressure SW = on = D-IN-18: Not used
low level) D-IN-19: Not used
00000000 (Not used) D-IN-20: Air cleaner clogging
Input signal D_IN_16- The state of input signal is 00000000 (Not used) D-IN-21: Not used
34 40902 D-IN-16-----23
23 displayed 00001000 (Air cleaner clogging SW = on) D-IN-22: Parking brake emergency
00000000 (Not used) release SW
00000010 (Parking brake emergency release SW D-IN-23: Load meter total weight
= on) display SW
00000001 (Load meter total weight display SW = (Only when optional setting is made
on) in load meter)
D-IN-24: T/M filter clogging
10000000 (T/M filter clogging SW = on)
(Only when optional setting is made)
00000000 (Not used)
D-IN-25: Not used
00100000 (Parking brake = on)
D-IN-26: Parking brake
00010000 (Coolant level SW = on = low level)
Input signal D_IN_24- The state of input signal is D-IN-27: Coolant level
35 40903 D-IN-24-----31 00000000 (Not used)
31 displayed D-IN-28: Not used
00000100 (Engine oil level SW = on = low level)
D-IN-29: Engine oil level
00000010 (Emergency steering operation SW =
D-IN-30: Emergency steering opera-
on)
tion (Low S/T pressure)
00000000 (Not used)
D-IN-31: Not used
D-IN-32: Subtotal SW
(Only when optional setting is made
10000000 (Subtotal SW = on) in Load meter)
01000000 (Cancel SW = on) D-IN-33: Cancel SW
00100000 (High beam = on) (Only when optional setting is made
Input signal D_IN_32- The state of input signal is 00000000 (Not used) in Load meter)
36 40904 D-IN-32-----39
39 displayed 00001000 (SW for servicing = on) D-IN-34: High beam
00000100 (Monitor mode SW (>) = on) D-IN-35: Not used
00000010 (Monitor mode SW (<) = on) D-IN-36: SW for servicing
00000000 (Not used) D-IN-37: Monitor mode SW (>)
D-IN-38: Monitor mode SW (<)
D-IN-39: Not used
1000 (Buzzer = on) D-OUT-0: Buzzer
Output signal The state of output signal is 0000 (Not used) D-OUT-1: Not used
37 40952 D-OUT-0--3
D_OUT_0-3 displayed 0000 (Not used) D-OUT-2: Not used
0000 (Not used) D-OUT-3: Not used
WA500-6 35
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10 Structure, function and maintenance standard SEN00712-04
No injection cranking
For the starting method of engine using this function, see “Testing and adjusting: No injection cranking oper-
ation of engine”.
This section describes only the operating method.
WA500-6 37
SEN00712-04 10 Structure, function and maintenance standard
Adjustment function
For adjustment using this function, see “Testing and
adjusting: Adjustment performed on the monitor”.
This section describes its outline only.
38 WA500-6
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WA500-6 39
SEN00712-04 10 Structure, function and maintenance standard
Pressing the U switch changes the screen to the “Item NO. 1 is displayed” screen.
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10 Structure, function and maintenance standard SEN00712-04
4. Selection between timer stop for all items and enable by item
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SEN00712-04 10 Structure, function and maintenance standard
Outline
q The value of fuel consumption is obtained by adding the target injection amount sent from the engine
controller.
q It is not measured but calculated fuel consumption. Use it as a rough standard.
*1 The upper column displays fuel consumption The lower column displays the travel distance
[L/km or L/mile] per 1 km (or 1 mile) from the [km or mile] from the last resetting.
last resetting. The unit km or mile shall be selected depend-
It is calculated from the fuel consumption and ing on that used on the odometer.
travel distance above. The counting is stopped at 9999999.9, the
The unit km or mile shall be selected depend- upper limit.
ing on that used on the odometer.
The counting is stopped at 99999.9, the upper *3 The upper column displays the cumulative fuel
limit. consumption [L] from the last resetting.
The lower column displays the average fuel The counting is stopped at 9999999.9, the
consumption [L/h] from the last resetting. upper limit.
The counting is stopped at 99999.9, the upper The lower column displays the elapsed time [h]
limit. from the last resetting.
The counting is stopped at 9999999.9, the
*2 The upper column displays the cumulative fuel upper limit.
consumption [L] from the last resetting.
The counting is stopped at 9999999.9, the
upper limit.
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*4 Calculation of (*4) is executed when the load 8) If t switch is pressed before finishing
meter is installed. (The screen is not available entering, the cursor moves to the sign
when the load meter is not installed.) position. In this case, the value remains
The upper column displays the loaded volume unchanged. Using the t switch, return to
[ton] from the last resetting. the previous screen.
The counting is stopped at 199999999.9, the 9) If the value confirmed for the lowest-order
upper limit. digit is outside the range from –50.0 to
Short ton or metric ton depends on optional +50.0, the cursor moves to the sign posi-
setting. tion with the value unchanged as with
The lower column displays the loading fre- when the t switch is pressed.
quency from the last resetting.
The counting is stopped at 65000, the upper Processing on the monitor panel:
limit. q Default value: 0.0%
(*1 – *4) q This setting allows correcting the cumulative
Calculation is done only for the duration in fuel consumption (L) in the range of –50.0 to
which the engine is run. +50.0%.
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SEN00712-04 10 Structure, function and maintenance standard
3. Reduction/addition mode
q When addition mode is selected, “TOTAL q When reduction mode is selected, “REMAIN-
LOADED” is displayed at the display of addi- ING TARGET” is displayed at the display of
tion mode (1), which indicates the value reduction mode (1), which indicates the value
obtained by adding the value at the display of obtained by reducing the value at the display of
calculated bucket-loaded volume (3) to the calculated bucket-loaded volume (3) from the
value at the total loaded volume (2). value specified at the display of total loaded
q Weight calculation can be displayed by cumu- volume (2).
lating up to any 5 working objects indepen- q Weight calculation can be displayed by cumu-
dently. lating up to any 5 working objects indepen-
Working objects can be selected from types A dently.
to E at the working object display (4) in mode Working objects can be selected from types A
selection. to E at the working object display (4) in mode
q The display of total loaded volume (2) indi- selection.
cates up to 9,999 t unless data is cleared by
the load meter subtotal switch. a For the display and calculation method when
The display indicates a value to one decimal the value at the display of bucket-loaded vol-
place (in 100 kg) in the case of max. 999.9 t. ume (3) exceeds the value at the display of
When it exceeds 1000 t, the decimal point dis- remaining volume (2), see Operation and
play disappears and switches to the display in Maintenance Manual “Handling the load
1 t. meter”.
a For details of the display of remaining volume,
a For details of the display of total loaded vol- see “Display of total loaded volume and dis-
ume, see “Display of total loaded volume and play of remaining volume”.
display of remaining volume”.
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10 Structure, function and maintenance standard SEN00712-04
Display of total loaded volume and display of Load meter subtotal switch
remaining volume
Display of
Actual total loaded
total loaded Remarks
weight (t)
volume
– –99.5 –99.9 Display of decimal point
Display of decimal point
–99.4 – –0.1 –**.* (the second decimal
place is rounded off.)
Display of decimal point
0 – 999.4 ***.* (the second decimal
place is rounded off.)
Display of integer
999.5 – 9999.4 **** (the second decimal
place is rounded off.)
q To clear the display of total loaded volume (in
9999.5 – 9999 Display of integer
addition mode) or display of remaining volume
Unit of calculated weight (in reduction mode), continuously press the
q Calculated weight values are all displayed in SI switch (1) at least 2 seconds.
(metric ton).
If “MPH” has been selected for speed display Specifications Operation after operating switch
in monitor setting, however, it can be switched Printer not Clears the display of total loaded volume (dis-
to short ton (US ton) in service mode optional installed play of remaining volume).
setting. Printer Outputs saved subtotal data on the printer.
If you switch it to short ton, weight display is installed After the output, the subtotal data is cleared.
also output in short ton (US to) on the printer.
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10 Structure, function and maintenance standard SEN00712-04
Reset of data
q Cumulative data by the item (A) to (E) or of all objects are reset.
q Display “TOTAL DATA” on the character display. Press the load meter selector switch (A/B) to specify
either “By the item (A) to (E) or “All ON” at the working object display. Press the load meter mode selec-
tor switch (A/B) at least 4 seconds.
The output format of load meter can be selected from 3 types (A, B, C) of output mode.
The output format of each mode is as follows.
a For selection of output mode and output method, see Operation and Maintenance Manual “Han-
dling the load meter”.
A-mode B-mode C-mode
(Total printer output) (Subtotal printer output) (Operation record printer output)
• Model, serial number • Model, serial number • Model, serial number
• Date and time of printing • Date and time of printing • Date and time of starting record, service
• Subtotal loading data • Loading data meter
(Type/number of loading/loaded volume) (Loaded volume) • Date and time of ending record (printing),
• Total loading data • Subtotal loading data service meter
(Total number of loading/Total loaded vol- (Type/number of loading/loaded volume) • Subtotal loading data
ume) • Total loading data (Type/number of loading/loaded volume)
(Total number of loading/Total loaded vol- • Total loading data
ume) (Total number of loading/Total loaded vol-
ume)
• Maintenance time
(Maintenance item/remaining time)
WA500-6 53
SEN00712-04 10 Structure, function and maintenance standard
1) No load calibration
q This function cancels the individual differ-
ence of weight inherent to the machine,
a For the calibration execution method, see
e.g. the weight of working equipment. It
“Testing and adjusting: Testing and adjust-
makes compensation (B) by offsetting the
ing the load meter”.
error between the actual weight and the
reference value (A) as shown below.
7. Calculation stop
The calculation function of the load meter is
stopped.
During the calculation stop, the display of load
meter disappears, and speed display or engine
speed display appears. No data is added to the
total data in this mode.
To restart calculation, select the addition mode
or reduction mode.
a For the calculation stop method, see
“Operation and Maintenance Manual:
Handling the load meter”.
Function of troubleshooting
The machine monitors the input and output signals
constantly for troubleshooting for the system.
If any abnormality is detected by self-diagnosis, the
information on it is transmitted through the network
to the machine monitor. When abnormality occurs,
it can be confirmed on the machine monitor (display
of failure history).
54 WA500-6
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WA500-6 55
SEN00712-04 10 Structure, function and maintenance standard
Do not change settings of spare rotary switches and spare DIP switches.
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10 Structure, function and maintenance standard SEN00712-04
WA500-6 63
SEN00712-04
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
64
SEN00713-02
WA500-6
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10 Structure, function and maintenance standard SEN00713-02
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10 Structure, function and maintenance standard SEN00713-02
Function
q The work equipment controller operates the work equipment by detecting the operating stroke
of raise/lower, tilt/dump from the signals of the work equipment lever potentiometer, and oper-
ating the main spool by operating each EPC valve attached to the main valve with current con-
trol.
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SEN00713-02 10 Structure, function and maintenance standard
q The work equipment control lever is equipped with detent notches, and it is adjusted so that it
will operate at the maximum speed before each detent. The range beyond lower detent is the
“lift arm float” operation position, where the lift arm operates by external forces.
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10 Structure, function and maintenance standard SEN00713-02
Function
q When the work equipment lock lever is operated to the lock position, the lock switch (baffle
lever switch) becomes OPEN, and the controller stops the operation of the work equipment by
turning ON the work equipment neutral lock valve, cutting EPC pilot basic pressure.
a While the work equipment is locked, the detent does not operate, and the lever is not held at
the detent position.
q The safety function, in which the work equipment is continued to be locked until the work
equipment control lever is temporarily returned to the neutral position, even if the work equip-
ment is unlocked, is incorporated.
Operation table
Operation by Operation of
Input of controller Work equipment control Output of controller
man machine
Work equipment lever Work equipment Oil
Baffle lever Baffle lever switch
potentiometer neutral lock valve pressure
Lower OFF ON
— Cut
(LOCK) (OPEN) (24V)
Lower to raise OFF Work equipment control lever being ON
Cut
(unlocking) (OPEN) operated (24V)
Lower to raise OFF After releasing, lever neutral of all OFF
Operating
(unlocking) (OPEN) work equipment detected once (OPEN)
Raise ON OFF
— Operating
(FREE) (CLOSE) (OPEN)
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SEN00713-02 10 Structure, function and maintenance standard
Function
q The work equipment control lever has neutral play of 5% in the lever stroke, and it is adjusted
so that the work equipment will start working from the position beyond the play.
q It also has a function to change the work equipment speed for the lever stroke through setting
of the controllers.
q The lift arm has five changeable tables, and the bucket has three.
a For the adjustment method and the characteristics of each table, refer to “Testing and adjust-
ing: changing the lift arm table or changing the bucket table.”
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10 Structure, function and maintenance standard SEN00713-02
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SEN00713-02 10 Structure, function and maintenance standard
Function
q Because CLSS is employed in this machine, although the bucket and the lift arm can be oper-
ated simultaneously, it has a function that prevents the lift arm from rising when the tilt operat-
ing stroke is large, for more efficient digging.
q It is realized by limiting the maximum speed of lift arm raise (table below) for the tilt speed.
a This function does not work in dump operation, which enables the simultaneous operation.
Bucket tilt speed 0% 20% 40% 60% 70% 100%
Maximum speed of lift arm raise 100% 80% 30% 0% 0% 0%
Function
q The work equipment controller operates modulation, when the lift arm stop operation is per-
formed more suddenly than a certain speed by the operator, for easing stop shock of lift arm
raise/lower.
q The operation of this stop modulation function can be changed through setting.
a For the method to change and precautions, refer to “Testing and adjusting: changing the lift
arm stop modulation.”
Case A:
In the case of lever command flow rate < modulation command flow rate
q Outputs according to the lever command flow rate
Case B:
In the case of lever command flow rate > modulation command flow rate
q Outputs according to the modulation command flow rate
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10 Structure, function and maintenance standard SEN00713-02
Function
q It implements the equivalent function as the cut-off function, performed with the cut-off valve in
the conventional machine (WA500-3).
q Lift arm above horizontal (Lift arm angle sensor signal)
q Bucket tilt end (Tilt end proximity switch signal)
q Lift arm bottom pressure minimum 20 MPa (Signal by network communication from the
monitor)
Only when the above conditions are simultaneously satisfied, the lift arm raise maximum speed
will be limited to 70%.
q When the lift arm raise maximum speed is changed between 70% and 100%, modulation is
equipped for reducing shocks, controlling so that the speed will not change suddenly.
q This function can change the condition value of the lift arm bottom pressure through controller
setting. By changing the set value of the lift arm bottom pressure, matching of the lift arm rising
speed and travel speed can be changed.
a For the method to change and procedure, refer to “Testing and adjusting: adjusting pump cut-
off pressure.”
Function
q The work equipment controller has an adjusting function for correction dispersion.
q The detent position is adjusted so that the lever potentiometer voltage at the detent position
will be saved, ensuring control before and after the detent. When it is not adjusted, such phe-
nomena as “the positioner does not operate normally before and after the detent,” or “the lever
position of lift arm float is not normal” may occur.
q When the work equipment starting current is not adjusted, such phenomena as “the neutral
dead zone is large” or “dashing/stopping shock of the work equipment becomes large” may
occur.
a For the adjusting procedure, refer to “Testing and adjusting: adjusting the work equipment EPC
lever detent position/adjusting starting current.”
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SEN00713-02 10 Structure, function and maintenance standard
2. Remote positioner
1) Bucket positioner
Function
q This is a function that the bucket will gently stop at any set position, when the tilt lever is set to
the detent position with the bucket level or lower.
Condition for
Bucket lever stroke: neutral and travel speed below 5 km/h
availability
(1) When setting it upward from the current stop position, press the bucket positioner +
position set switch position (upward). (Use the downward switch to change it down-
ward)
(2) Saves +1 to the current set position (memory), sounds a setting complete buzzer (pip)
and the monitor displays the numerical value for 3 seconds
Setting method
(Set position will be maintained when the key is turned off.)
* When the switch is operated exceeding ±5 of the set range, the monitor displays the
same value, and the setting cancel buzzer (pip) sounds.
(3) For further change, release the switch once, and then press it again.
(when *, the same as (2))
12 WA500-6
10 Structure, function and maintenance standard SEN00713-02
Delay time:
The bucket horizontal proximity switch is set at the position where the bucket is “down-
ward (–5).”
The flow rate to the tilt cylinder is calculated from the pump delivery, and, when the neces-
sary oil level for the set position is reached, the detent will be reset and it will stop gently.
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SEN00713-02 10 Structure, function and maintenance standard
Function
a) Raise kick-out (when raise lamp is on)
Set the lift arm lever to “raise detent,” reset the lift arm raise detent when the lift arm rises before the
set position, and perform stop (gentle) control.
When the lift arm is at other positions than the “raise detent,” it is raised with operation by the oper-
ator.
When raise is not selected, only raise detent will operate.
When the detent is turned on, the remote positioner will not operate, and only the kick-out function
(stop at the top position of the lift arm) will operate.
a The remote positioner of lower will not function as positioner, and will not stop, when the detent is
turned on with the lift arm angle level or lower, in order to distinguish it from float operation in grad-
ing operation.
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4] Boom kick-out
q When the lift arm raise detent is set when the stop position of the remote positioner is not
set or above the stop position, the lift arm slowly stops before the stroke end as kick-out
operation, reducing stop shock due to stroke end.
q In kick-out operation, the detent becomes off from 2° before stop angle to 2.5° past.
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10 Structure, function and maintenance standard SEN00713-02
4. Semi-automatic digging
Function
Control of semi-automatic digging
q Semi-automatic digging is a function, in which digging operation can easily be performed only with
the kick-down switch and lift arm raise operation, improving the working efficiency of less experi-
enced operators, and the two modes of LOOSE mode/ROCK mode are separately used due to the
characteristics of work objects.
q Select the bucket automatic operation pattern appropriate for work cycle/load
Mode selection No. Object Mode
1 Gravel/sand LOOSE mode
2 Quarry/blasted rock ROCK mode
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SEN00713-02 10 Structure, function and maintenance standard
q Tilt operation will start 0.5 seconds after the conditions for starting semi-automatic digging
are satisfied.
q The speed is increased so that it becomes 100% 10 seconds after starting tilt, the maxi-
mum speed depends on engine speed.
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10 Structure, function and maintenance standard SEN00713-02
q Tilt operation will start 0.6 seconds after the conditions for starting semi-automatic digging
are satisfied.
q Tilt repeats operation/stop, with different tilt time/cycle for each cycle, and the number of
tilts changes until loading is finished in accordance with loading object.
q The maximum speed depends on engine speed.
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SEN00713-02 10 Structure, function and maintenance standard
Function
In pump swash plate control, “horsepower loss decrease function in pump relief” and “pickup auxiliary
function when engine speed is low” are included, and based on calculation results of each function, data
with less pump delivery (larger pump EPC current) will be selected.
q The work equipment controller operates pump EPC in 200 mA until loader pump pressure
reaches 32 MPa {330 kg/cm2}, and when it becomes 33 MPa {340 kg/cm2} or higher, the con-
troller operates pump EPC in 700 mA.
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10 Structure, function and maintenance standard SEN00713-02
q In this control, the delivery (pump EPC current) is changed over a second from 700 mA to 200 mA in
order to prevent sudden operation due to rapid increase of flow rate, when the delivery changes in
increasing direction (current decreasing direction).
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10 Structure, function and maintenance standard SEN00713-02
q The work equipment controller operates pump EPC in 900 mA until engine speed reaches 500
rpm, and when it becomes 1,400 rpm or higher, the controller operates pump EPC in 200 mA.
Engine Speed Current value (mA) Pump flow rate
500 rpm 900 MIN
1,000 rpm 569 C 40%
1,400 rpm 200 100%
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SEN00713-02 10 Structure, function and maintenance standard
Function
1) Joystick Steering (J/S) system
q Joystick steering controls the turning speed according to the joystick lever operation angle.
q Standard steering system is added with a system for implementing Orbit-roll operation using
joystick solenoid valve.
q Therefore, even during a joystick steering operation, turning operation can be made using the
steering wheel.
q Transmission controller controls validity/invalidity of joystick steering system. When the
machine monitor joystick indicator is other than lit (turned out or flashing), turning operation
can not be made using the joystick lever.
26 WA500-6
10 Structure, function and maintenance standard SEN00713-02
5) Joystick setting
q Since the joystick is an optional equipment, control will not be performed unless the option set-
ting for joystick is made valid in the optional setting of the machine monitor. It cannot be simul-
taneously installed with the right FNR switch.
a For the setting procedure of options, refer to “Testing and adjusting: Select optional equip-
ment.”
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SEN00713-02 10 Structure, function and maintenance standard
7. Real-time monitor
1) List of display contents of the real-time monitor
In WA500-6, the state of the controller input and output signals can be checked using the real-time
monitor function of the monitor.
The following table shows the display items and display contents in normal operation of the real-
time monitor in relation to the work equipment controller:
Display of Contents of Display contents in
No. Check item ID No. Remarks
item name display data normal operation
Software part Part No. of software is dis- Depends on the software
1 20202 VERSION
number played number
Application Ver- Application version num- Depends on application
2 20225 VERSION APP
sion ber is displayed version number
Data version number is Depends on data version
3 Data Version 20226 VERSION DATA
displayed number
When work equipment is
Converted value of the in neutral
Loader pump
4 94700 PUMP PRESS loader pump oil pressure : 2.0±2.0 MPa
pressure
is displayed Work equipment relief
: 34.0±2.0 MPa
When work equipment is
Input voltage value of in neutral
Loader pump
5 94701 PUMP PRESS loader pump oil pressure : 0.70±0.2 V
pressure
is displayed Work equipment relief
: 3.22±0.2 V
Li (800 rpm)
: 421±30 mA
Hi (above 950 rpm)
Loader pump Loader pump EPC OUT : 200±10 mA
6 EPC current 94500 PUMP EPC DIR command current value is Work equipment relief
(Command) displayed : 700±10 mA
Engine stop (below 500
rpm)
: 900±10 mA
When work equipment is
in neutral:
Pump delivery Results of pump delivery
7 94600 PUMP FLOW 170 CC/R
flow rate calculation are displayed
Work equipment in relief:
23±10 CC/R
Standard lift arm
Lift arm top
: 47.0±2.0 deg
Lift arm bottom
Calculation results of lift : -43.0±3.0 deg
8 Lift arm angle 06002 BOOM ANG
arm angle is displayed Hi-lift lift arm
Lift arm top
: **.*±2.0 deg
Lift arm bottom
: -**.*±3.0 deg
STD lift arm
Lift arm top:
3.80±0.3 V
Lift arm bottom:
Input voltage value to lift
1.31±0.5 V
9 Lift arm angle 06005 BOOM ANG arm angle sensor potenti-
Hi-lift lift arm
ometer is displayed
Lift arm top:
**.*±0.3 V
Lift arm bottom:
**.*±0.5 V
Operation angle con- In WA500-6,
verted value of AJSS there is no cor-
10 Frame angle 94400 FRAME ANGLE —
frame potentiometer is responding
displayed functions
Number of lift Number of lift arm lever Display in accordance
11 arm lever opera- 42100 BOOM LVR operations is displayed in with the number of lever
tions the unit of thousand operations
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Input signal
D_IN_32-39 There is no used items in
(No. 33-39 The state of input signal this data
40 40942 D-IN-32-----39
don't apply to is displayed 00000000 is constantly
work equipment displayed
controller.)
D-OUT-0
10000000 : Work equip-
(Lock position) ment N Lock
00000000 SOL
(Unlock neutral) D-OUT-1
ON/OFF output state of
01000000 : Lift arm raise
ON/OFF output SOL_OUT0 to 7
41 40952 D-OUT--0------7 (Raise detent SOL = ON) detent SOL
D_OUT_0--7 '0' is displayed when set-
00100000 D-OUT-2
ting current output
(Float detent SOL = ON) : lift arm float
0001000 detent SOL
(Tilt detent D-OUT-3
. SOL = ON) : Bucket tilt
detent SOL
WA500-6 31
SEN00713-02 10 Structure, function and maintenance standard
32 WA500-6
10 Structure, function and maintenance standard SEN00713-02
8. Diagnosis
1) Function of troubleshooting
The work equipment controller monitors the input and output signals constantly for troubleshooting
for the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor. When abnormality occurs, it can be confirmed on the machine moni-
tor/KOMTRAX.
WA500-6 33
SEN00713-02 10 Structure, function and maintenance standard
9. Pin assignment
34 WA500-6
10 Structure, function and maintenance standard SEN00713-02
DEUTSCH-40P(1) [CN-L06]
Input and Input and
Pin No. Signal name Pin No. Signal name
output signals output signals
1 NC Output 21 NC Input and output
2 NC Input 22 COMM_CAN_L_O Input and output
3 Remote positioner leveling set SW. Input 23 NC Input and output
4 NC Input 24 PWR_CTR_EXT Input
5 NC Input 25 Starting switch (IGN-C) Input
6 NC Input 26 NC Input
7 NC Input 27 NC Input
8 NC Output 28 NC Input
9 NC Output 29 NC
10 NC Input 30 NC Input
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input and output
13 Remote positioner lifting set SW. Input 33 NC Input and output
14 NC Output 34 NC
15 NC Input 35 Lever prohibiting equipment SW. Input
16 NC Input 36 NC Input
17 NC Input 37 NC Input
18 NC Output 38 NC Input
19 NC Output 39 NC
20 NC Input 40 NC Input
DEUTSCH-40P(2) [CN-L07]
Input and out- Input and out-
Pin No. Signal name Pin No. Signal name
put signals put signals
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 Safety relay Output 24 PWR_CTR_KEY Input
5 Bucket tilting EPC Output 25 Third EXT EPC Output
6 Boom lifting EPC Output 26 J/S solenoid cut relay Output
7 Work neutral lock solenoid Output 27 Magnetic detent of boom lever float Output
8 Remote positioner lifting indicator Output 28 J/S right EPC Output
9 NC Input 29 NC Input
10 Bucket cylinder tilt end SW. Input 30 Bucket positioner up set SW. Input
11 PWR_IN_BATT Input 31 GND_PWR
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 Bucket dumping EPC Output 35 Third RET EPC Output
16 Boom lowering EPC Output 36 Loader pump EPC Output
17 Magnetic detent of boom lever lift Output 37 Magnetic detent of bucket lever tilt Output
18 Remote positioner lowering indicator Output 38 J/S left EPC Output
19 NC Input 39 NC Input
20 Bucket cylinder horizon SW. Input 40 Bucket positioner down set SW. Input
WA500-6 35
SEN00713-02 10 Structure, function and maintenance standard
36 WA500-6
10 Structure, function and maintenance standard SEN00713-02
WA500-6 37
SEN00713-02 10 Structure, function and maintenance standard
2) Display of gearshift
The transmission controller displays the state of input signal related to gearshift by sending to the
machine monitor via network.
1] Directional indicators
The directional indicators of the machine monitor display the signal input state of the directional
lever, which is input to the transmission controller. Therefore, when the lever is in neutral posi-
tion, and there is no input signal to the transmission controller, the directional indicators totally
go out, and if two signals are input due to a problem, the two indicators may light up at the
same time.
If the directional lever is in “R” state, the backup lamp relay will be operated, and the back lamp
and back buzzer will be operated.
For the indication for the case where the machine is installed with right FNR switch (if
equipped) and the joystick steering (if equipped) with two systems of FNR signal, refer to the
items in the “Optional functions.”
38 WA500-6
10 Structure, function and maintenance standard SEN00713-02
5) Kickdown function
1] Kickdown in manual shift operation
q The kickdown switch operates only in the forward 2nd gear speed (F2), and the transmis-
sion is set in the forward 1st gear speed (F1). Operation of the kickdown switch is ignored
in any gear speed other than (F2).
q After the actual gear speed becomes (F1) due to kickdown switch operation, the kickdown
function will be released and the transmission will be set in the gear speed of the lever,
when the directional lever is operated to a position other than forward, or the gearshift
lever is operated to a position other than the 2nd gear speed.
WA500-6 39
SEN00713-02 10 Structure, function and maintenance standard
*1: When lockup is released due to kickdown switch operation, lockup will not be ON again
until the following conditions are satisfied.
a Perform temporary operation to turn the torque converter lockup switch OFF o ON.
a The travel speed changes from below to above lockup ON speed as listed in the Auto-shift
points table.
1] Lockup rotation
For ON/OFF of lockup, refer to “3: Auto-shift points table.”
40 WA500-6
10 Structure, function and maintenance standard SEN00713-02
WA500-6 41
SEN00713-02 10 Structure, function and maintenance standard
42 WA500-6
10 Structure, function and maintenance standard SEN00713-02
1] All range of auto modes (speed position switch at a position other than 1st gear speed) and
manual mode (2nd, 3rd, and 4th)
In auto-shift mode
Range I: F-R is changed and transmission is set in 2nd gear speed. (Ordinary range)
Range II: F-R is changed, transmission is set in 2nd gear speed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to 2nd gear speed with reduction of the travel
speed.
In manual-shift mode
Range I: Only F-R is changed. (Ordinary range)
Range II: F-R is changed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to the speed position with reduction of the travel
speed.
a Two seconds immediately after the F-R changing operation, shifting up/down and kick-
down switch operation will not be accepted, and if shifting up/down operation is performed
with the lever operation, gear shift will be performed in two seconds.
In auto-shift, shifting up will not be performed until 2nd gear speed is obtained by speed
reduction.
WA500-6 43
SEN00713-02 10 Structure, function and maintenance standard
q The shift-down protection is valid also in kickdown operation in auto-shift. If the machine is
traveling in travel speed above the protect condition when kickdown operation is performed,
the kickdown operation is not accepted, and the alarm goes ON for 3 seconds.
6) Neutralizer function
q When the parking brake switch is ON (while the parking brake switch is operating), transmis-
sion output is maintained in neutral regardless of the state of the gearshift lever, for parking
brake dragging prevention function.
q The parking brake switch circuit is a safety circuit, which will be not open when the key switch
is changed from OFF to ON. Therefore, while the key is on, transmission is always in neutral
regardless of the state of the lever.
44 WA500-6
10 Structure, function and maintenance standard SEN00713-02
5. Engine control
3) Throttle lock
q For improving the working efficiency, the engine speed is maintained at an arbitrary speed.
q The engine speed is set with pressing the accelerator pedal, and RMP set idle up/down switch.
q When the right brake is pressed, throttle lock is temporarily released.
q For lower fuel consumption, in a setting with auto deceleration function, if the transmission
neutral continues for 4 seconds or the work equipment neutral state lasts for 4 seconds or
longer, if the throttle lock SET/ACCEL SW and throttle lock RESUME/DECEL SW are not oper-
ated, and if the travel speed is 5 km/h or less, the throttle lock function is temporarily released,
and transmission follows the signal of the accelerator pedal.
q In the state where the throttle lock is temporarily released, if the transmission is set to a posi-
tion other than neutral, or the work equipment is in a state other than N, the throttle control
state will be resumed automatically.
WA500-6 45
SEN00713-02 10 Structure, function and maintenance standard
q For description of the throttle lock function, a sample time chart is shown below.
46 WA500-6
10 Structure, function and maintenance standard SEN00713-02
6. Transmission cut-off
WA500-6 47
SEN00713-02 10 Structure, function and maintenance standard
2] Outputting conditions for buzzer, indicator (main monitor), and indicator in transmission cut-off
switch
Indicator in trans- Buzzer command
Output conditions mission cut-off (Communication Cut-off point
switch output)
When transmission cut-off switch is Controlled with value
ON Not displayed
“ON“ saved last
2.5 seconds when transmission cut-
When set switch is Controls with previously
off switch is “ON” and transmission Blinking
pressed, set com- saved value
cut-off set switch is “ON” or resetting (2.6 sec or until
pletion buzzer Saves the pressure that
(while sensor being normal) and set- reset)
sounds pressed the set switch
ting method being (2) to (5).
When transmission cut-off switch is Not displayed No control is made
“ON” and pressure sensor is abnor- Remains turned out (Error buzzer Saved value is not
mal (see FMEA) sounds) changed
Controlled with value
When transmission cut-off switch is Not displayed
saved previous time
“ON” and set switch is abnormal (see ON (Monitor displays
Saved value is not
FMEA) error)
changed
When transmission cut-off switch is
“ON” and transmission cut-off set Set cancel buzzer Controls with previously
switch is “ON“ ON sounds when set saved value
switch is pressed Saves the default
Reset within 2.5 sec
When transmission cut-off switch is
OFF Not displayed Not controlled
“OFF“
a During cut-off, actual transmission gear speed will be indication as N (neutral). (FNR out-
put number will be “N“)
a During lockup, lockup will be cancelled to implement cut-off.
a If cut-off is made after reaching 1st speed with kickdown switch, gear should return to 1st
gear speed for both auto/manual shift.
48 WA500-6
10 Structure, function and maintenance standard SEN00713-02
7. ECSS
1) ECSS function
q It is a system in which the controller automatically turns on and off the accumulator charged
with high-pressure gas according to the travel condition, and the lift arm operation condition,
improving operator comfort and working efficiency by preventing spillage of material by absorb-
ing the vertical movement of the work equipment, when the vehicle travels at high speed.
2] Operation of ECSS
q The operating condition of ECSS is as follows.
Since the ECSS is optional equipment, control will not be performed unless the option of
ECSS is enabled in the optional setting of the machine monitor.
a For the setting procedure of options, refer to “Testing and adjusting: Select optional equip-
ment.”
Output shaft
ECSS switch Gear speed ECSS output
speed
OFF All 0 to MAX OFF
1st 0 to MAX OFF
ON Condition A OFF
2nd to 4th
Condition B ON
WA500-6 49
SEN00713-02 10 Structure, function and maintenance standard
8. Economy lamp
1) Control of economy lamp
q The transmission controller lights up the economy lamp indicator of the machine monitor when
operating in low fuel consumption, in order to prompt low fuel consumption operation to the
operator.
50 WA500-6
10 Structure, function and maintenance standard SEN00713-02
WA500-6 51
SEN00713-02 10 Structure, function and maintenance standard
q Fan speed
3) Protection function
q In order to prevent overrun of the cooling fan motor, this function minimizes the swash plate
angle of the cooling fan pump as the engine speed reached 2,300 rpm or above.
q If the transmission controller fails to recognize the engine speed and respective temperature
data due to a failure on the network communication, this function sends a specific command
current (677 mA) to the swash plate angle control EPC valve on the pump so that the pump
may work functionally – equivalent to a fixed pump.
52 WA500-6
10 Structure, function and maintenance standard SEN00713-02
WA500-6 53
SEN00713-02 10 Structure, function and maintenance standard
q Changing from forward to reverse, and reverse to forward is performed when the following
conditions are satisfied.
q The fan manual reverse switch is pressed
q The engine speed is 500 rpm or lower.
q The fan reverse indicator flashes when the state of the fan manual reverse switch and the
rotation direction of the fan do not match. While the fan is rotating in reverse direction, the
fan reverse indicator lights up.
Reverse SOL out- Forward/reverse
Reverse SOL Fan pump EPC Monitor indicator lighting
put before switch selector switch Engine speed
output output logic
operation operation
OFF From OFF to ON ON MIN speed From OFF to ON
OFF From ON to OFF OFF Ordinary From flashing to OFF
Below 500 rpm
ON From OFF to ON ON MIN speed From flashing to ON
ON From ON to OFF OFF Ordinary From ON to OFF
OFF From OFF to ON OFF Ordinary From OFF to flashing
OFF From ON to OFF OFF Ordinary From flashing to OFF
Min. 500 rpm
ON From OFF to ON ON MAX speed From flashing to ON
ON From ON to OFF ON MAX speed From ON to flashing
54 WA500-6
10 Structure, function and maintenance standard SEN00713-02
q Switching condition to the right FNR switch will be to turn the right FNR validity switch ON
when the standard FNR lever is at N (neutral) and the right FNR switch is at N (neutral). Only
then the switching of travel direction is enabled with the right FNR switch.
a When the travel direction is selectable with the right FNR switch, the right FNR indicator on the
machine monitor is lit.
a If either one of the switches is at other than N (neutral) and the right FNR validity switch ON-
OFF is operated, the buzzer will be actuated and right FNR indicator flashes on the machine
monitor.
q In addition, even if the right FNR switch is enabled, if the standard FNR lever is operated to
other than N (F or R), the standard FNR lever will have the priority. As the result, the standard
FNR lever will control the travel direction. Since the switching has not been made normally, the
warning will be actuated and the right FNR indicator on the machine monitor will start flashing.
a The alarm is actuated and the right FNR indicator started flashing, the alarm will not stop
unless and until both the standard and the right FNR switches are set to N (neutral), and the
right FNR switch will not function to effect forward-reverse travel.
WA500-6 55
SEN00713-02 10 Structure, function and maintenance standard
11. Joystick
a Switching conditions of the joystick to the FNR switch (hereinafter referred to as the joystick
switch) are as follows:
Selection of the travel direction becomes enabled with the joystick switch by turning the joy-
stick validity switch ON and canceling the joystick lock lever while the “standard FNR lever is at
N (neutral)” and the “joystick switch is at N (neutral).”
When the travel direction is selectable with the joystick switch, the joystick indicator on the
machine monitor is lit.
If either one of the switches is at other than N (neutral) and the joystick validity switch ON/OFF
is operated, the alarm will be actuated and the joystick indicator flashes on the machine moni-
tor.
q In addition, even if the joystick switch is enabled, if the standard FNR lever is operated to other
than N (F or R), the standard FNR lever will have the priority. As the result, the standard FNR
lever will control the forward-reverse travel. Since the switching has not been made normally,
the alarm will be actuated and the joystick indicator on the machine monitor will start flashing.
Once the alarm is actuated and the joystick indicator started flashing, the alarm will not stop
unless and until both the standard FNR lever and the joystick switches are set to N (neutral),
and the joystick switch will not function to effect forward-reverse travel.
q In the case the joystick indicator is not lit, forward and reverse operation are disabled, simulta-
neously the turning operation by the joystick also being disabled.
56 WA500-6
10 Structure, function and maintenance standard SEN00713-02
WA500-6 57
SEN00713-02 10 Structure, function and maintenance standard
q Also, in the case the joystick lever is operated when the joystick is in valid state, the work
equipment controller sends an engine start inhibit information to actuate the neutral safety
relay and cut the starting motor C terminal signal.
4) Joystick setting
q Since the joystick is an optional equipment, it makes no control unless the option setting for
joystick is made valid in the optional setting on the machine monitor.
q It cannot be simultaneously installed with the right FNR switch.
a For the setting procedure of options, refer to “Testing and adjusting: Select optional equip-
ment.”
58 WA500-6
10 Structure, function and maintenance standard SEN00713-02
WA500-6 59
SEN00713-02 10 Structure, function and maintenance standard
Display of
No. Check item ID No. Contents of display data Data unit (and range) Remarks
item name
Converted value of the
Displayed value
Transmission set oil pressure (IN oil
X1 [MPa] changes according
14 cut-off opera- 41203 T/M CUT SET pressure) to be trans-
(0.00 – 5.00 [MPa]) to the cut-off set
tion setting mission cut-off is dis-
operation
played
When the foot brake
is released:
0.00±0.1 MPa
Transmission
Converted value of the When foot brake is
cut-off X1 [MPa]
15 41201 T/M CUT OFF P brake oil pressure is dis- actuated:
(Left brake) (0.00 – 5.00 [MPa])
played Displayed value
pressure
changes according
to the brake-actuat-
ing operation
When the foot brake
is released:
1.00±0.1 V
Transmission
Input voltage value of When the foot brake
cut-off X1 [mV]
16 41202 T/M CUT OFF P brake oil pressure is dis- is actuated:
(Left brake) (0.00 – 5.00 [V])
played Displayed value
pressure
changes according
to the brake-actuat-
ing operation
Torque con-
TC SPEED Output torque converter X1 [%]
17 verter speed 93700
RATIO speed ratio (0 – 100 [%])
ratio
Transmission Output oil temperature
X1 [°C]
18 oil temperature 93600 T/M OIL TEMP value of transmission oil
(0 – 150 [°C])
input temperature (A_IN_1)
X1 [mV]
(0.00 – 5.00 [V])
Input voltage of Output input voltage 4.72 V = 0°C
19 transmission oil 93601 T/M OIL TEMP value of transmission oil 4.33 V = 30°C
temperature temperature (A_IN_1) 3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
MOD/C oil Not used by this
20 92400 MOD/C PRESS — —
pressure input machine
MOD/C oil
Not used by this
21 pressure input 92401 MOD/C PRESS — —
machine
voltage
MOD/C heat Not used by this
22 92500 MOD/C Q — —
release value machine
MOD/C heat Not used by this
23 92501 MOD/C q — —
ratio machine
Throttle lock
0:
switch (pressed
Output the state of input RPM set switch OFF
24 upward) 95500 THROT LOCK A
signal 1:
(RPM set
PRM set switch ON
switch)
Throttle lock
switch (pressed 0: RPM set auto deceler-
downward) Output the state of input ation switch OFF
25 95501 THROT LOCK B
(PRM set auto signal 1: RPM set auto deceler-
deceleration ation switch ON
switch)
Throttle correc- Output throttle correc-
THROTTLE X1 [%]
26 tion command 95400 tion command output
MOD (-100 – 100 [%])
output amount
Throttle open- Output throttle upper
THROT LIMIT X0.1 [%]
27 ing upper limit 44200 limit command output
UP (0.0 – 100.0 [%])
output amount
60 WA500-6
10 Structure, function and maintenance standard SEN00713-02
Display of
No. Check item ID No. Contents of display data Data unit (and range) Remarks
item name
Throttle open- Output throttle lower
THROT LIMIT X0.1 [%]
28 ing lower limit 44201 limit command output
LO (0.0 – 100.0 [%])
output amount
Depends on accelerator
pedal operation
Accelerator pedal = 0
Accelerator pedal partial
Depends on accelerator
pressing (opened side) =
Accelerator THROTTLE opening ratio; output
29 93801 1
mode MODE acceleration mode on
Accelerator pedal partial
control
pressing (pressed side) =
2
Accelerator pedal press-
ing = 3
Traction setting Not used by this
30 94000 TRACTION DIAL — —
input value machine
Traction setting Not used by this
31 94001 TRACTION DIAL — —
input voltage machine
0: Lockup changing
Lockup chang-
Output the state of input switch OFF
32 ing switch input 95000 LOCK UP SW
signal 1: Lockup changing
signal
switch ON
ECMV output to 1st
ECMV output
clutch X1 [mA]
33 command value 31602 ECMV 1 DIR
Output command cur- (0 – 1000 [mA])
(1st)
rent value
ECMV output to 2nd
ECMV output
clutch X1 [mA]
34 command value 31603 ECMV 2 DIR
Output command cur- (0 – 1000 [mA])
(2nd)
rent value
ECMV output to 3rd
ECMV output
clutch X1 [mA]
35 command value 31604 ECMV 3 DIR
Output command cur- (0 – 1000 [mA])
(3rd)
rent value
ECMV output to 4th
ECMV output
clutch X1 [mA]
36 command value 31605 ECMV 4 DIR
Output command cur- (0 – 1000 [mA])
(4th)
rent value
ECMV output to FWD
ECMV output
clutch X1 [mA]
37 command value 31608 ECMV F DIR
Output command cur- (0 – 1000 [mA])
(FWD)
rent value
ECMV output to L/U
ECMV output
clutch X1 [mA]
38 command value 31609 ECMV LU DIR
Output command cur- (0 – 1000 [mA])
(L/U)
rent value
ECMV output
ECMV MOD/C Not used by this
39 command value 31640 — —
DIR machine
(MOD/C)
ECMV output to REV
ECMV output
clutch X1 [mA]
40 command value 31606 ECMV R DIR
Output command cur- (0 – 1000 [mA])
(REV)
rent value
ECMV output Output to ECSS valve
X1 [mA]
41 command value 93300 ECSS V DIR Output command cur-
(0 – 1000 [mA])
(ECSS) rent value
Output 1st clutch fill time
value X0.01 [sec]
Fill time value
42 41802 FILL TIME 1 (State of gear change (0 – 2.55 [sec], No fill
(1st)
preceding immediately time: 0)
before)
WA500-6 61
SEN00713-02 10 Structure, function and maintenance standard
Display of
No. Check item ID No. Contents of display data Data unit (and range) Remarks
item name
Output 2nd clutch fill
time value X0.01 [sec]
Fill time value
43 41803 FILL TIME 2 (State of gear change (0 – 2.55 [sec], No fill
(2nd)
preceding immediately time: 0)
before)
Output 3rd clutch fill
time value X0.01 [sec]
Fill time value
44 41804 FILL TIME 3 (State of gear change (0 – 2.55[sec], No fill time:
(3rd)
preceding immediately 0)
before)
Output 4th clutch fill
time value X0.01 [sec]
Fill time value
45 41805 FILL TIME 4 (State of gear change (0 – 2.55 [sec], No fill
(4th)
preceding immediately time: 0)
before)
Output FWD clutch fill
time value X0.01 [sec]
Fill time value
46 41808 FILL TIME F (State of gear change (0 – 2.55 [sec],
(FWD)
preceding immediately No fill time: 0)
before)
Output REV clutch fill
time value X0.01 [sec]
Fill time value
47 41806 FILL TIME R (State of gear change (0 – 2.55 [sec],
(REV)
preceding immediately No fill time: 0)
before)
0*******
: Engine mode selector
SW OFF
1*******
: Engine mode selector
SW ON
*00*****
: (J/S shift-up/-down SW
D-IN0
not being operated)
: Engine mode
*10*****
selector SW
: (J/S shift-up SW being
D-IN1
operated)
: J/S shift-up SW
*01*****
D-IN2
: (J/S shift-down SW
: J/S shift-down SW
being operated)
D-IN3
***0****
: Air conditioner
: Air conditioner compres-
Input signal Output the state of input compressor operat-
48 40905 D-IN--0------7 sor stop
D_IN_0-7 signal ing
***1****
D-IN4
: Air conditioner compres-
: Shift mode L
sor operating
D-IN5
****00**
: Shift mode H
: Manual shift mode
D-IN6
****10**
: J/S or right FNR
: Shift mode L
valid SW
****11**
D-IN7
: Shift mode H
: C terminal signal
******0*
: Right FNR (J/S) selector
SW OFF
******1*
: Right FNR (J/S) selector
SW ON
*******1
: Cranking
62 WA500-6
10 Structure, function and maintenance standard SEN00713-02
Display of
No. Check item ID No. Contents of display data Data unit (and range) Remarks
item name
10**0***
: Transmission cut-off SW
ON
11**0***
: Transmission cut-off SW
AND setting SW ON
D-IN8
**0*0***
: Transmission cut-
: Kick-down SW OFF
off SW
**1*0***
D-IN9
: Kick-down SW ON
: Transmission cut-
***00***
off point set SW
: Shift hold SW OFF
D-IN10
***10***
: Kick-down SW
: Shift hold SW ON
D-IN11
Input signal Output the state of input ****00**
49 40906 D-IN--8-----15 : Shift hold SW
D_IN_8-15 signal : Throttle lock set SW
D-IN13
OFF
: Throttle lock set
****01**
SW
: Throttle lock set SW ON
D-IN14
****0*0*
: Throttle lock
: Throttle lock resume SW
resume SW
OFF
D-IN15
****0*1*
: Left brake pedal
: Throttle lock resume SW
SW
ON
****0**0
: Left brake pedal SW
OFF
****0**1
: Left brake pedal SW ON
D-IN16
1000****
: Gear speed lever
: Gear speed lever at 1st
1st speed
speed
D-IN17
0100****
: Gear speed lever
: Gear speed lever at 2nd
2nd speed
speed
D-IN18
0010****
: Gear speed lever
: Gear speed lever at 3rd
3rd speed
speed
D-IN19
0001****
: Gear speed lever
Input signal Output the state of input : Gear speed lever at 4th
50 40907 D-IN-16-----23 4th speed
D_IN_16-23 signal speed
D-IN20
****100*
: Direction lever at F
: Direction lever at F
D-IN21
****010*
: Direction lever at
: Direction lever at N
N
****001*
D-IN22
: Direction lever at R
: Direction lever at
*******0
R
: Parking brake released
D-IN23
*******1
: Parking brake sig-
: Parking brake operating
nal
WA500-6 63
SEN00713-02 10 Structure, function and maintenance standard
Display of
No. Check item ID No. Contents of display data Data unit (and range) Remarks
item name
D-IN24
: Right FNR (J/S
1******0 FNR) F
: Right FNR (J/S FNR) F D-IN25
0101000* : Fill SW at F
: Traveling at F1 D-IN26
0010100* : Fill SW at R
: Traveling at R2 D-IN27
Input signal Output the state of input 0000010* : Fill SW at 1st
51 40908 D-IN-24-----31
D_IN_24-31 signal : 3rd speed neutral D-IN28
0100001* : Fill SW at 2nd
: Traveling at F4 D-IN29
0******1 : Fill SW at 3rd
: Right FNR (J/S FNR) R D-IN30
0******0 : Fill SW at 4th
: Right FNR (J/S FNR) N D-IN31
: Right FNR (J/S
FNR) at R
1*******
: Right FNR (J/S FNR) at
Input signal
N
D_IN_32-39
0******* D-IN32
(Transmission Output the state of input
52 40942 D-IN-32-----39 : Right FNR (J/S FNR) at : Right FNR (J/
controller does signal
F SFNR) at N
not have 33 –
0*******
39)
: Right FNR (J/S FNR) at
R
0000**00
: Fan reverse solenoid
OFF
0001**00 D-OUT3
: Fan reverse solenoid : Fan reverse sole-
ON noid
000*0*00 D-OUT4
ON/OFF output state of
: Fan neutral solenoid : Fan neutral sole-
Output signal SOL_OUT0 to 7
53 40949 D-OUT 0-7 OFF noid
D_OUT_0-7 '0' is displayed when
000*1*00 (if equipped)
setting current output
: Fan neutral solenoid ON D-OUT5
000**000 : Low temperature
: Low temperature bypass bypass solenoid
solenoid OFF (Optional)
000**100
:Low temperature bypass
solenoid ON
ON/OFF output state of
SOL_OUT8 to 11B,
Output signal Not used by this
54 40950 D-OUT 8-15 SIG_OUT0 to 1 00000000
D_OUT_8-15 machine
'0' is displayed when
setting current output
ON/OFF output state of
SIG_OUT2 to 3,
Output signal HSW_OUT0 to 1, Not used by this
55 40951 D-OUT 16-23 00000000
D_OUT_16-23 BATT_RY_OUT machine
'0' is displayed when
setting current output
111111 16-bit data is dis-
Output initial learning
(all clutches learned) played
Initial learning flag state of trigger time
56 94100 TRIG FR1234 000000 in the order of F, R,
flag of each clutch
(all clutches to be 1, 2, 3, and 4 on the
[F,R,1,2,3,4]
learned) monitor
64 WA500-6
10 Structure, function and maintenance standard SEN00713-02
13. Diagnosis
1) Function of troubleshooting
The transmission controller monitors the input and output signals constantly for troubleshooting for
the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor.
When abnormality occurs, it can be confirmed on the machine monitor.
WA500-6 65
SEN00713-02 10 Structure, function and maintenance standard
66 WA500-6
10 Structure, function and maintenance standard SEN00713-02
DEUTSCH-40P(1) [CN-L03]
Input and out- Input and out-
Pin No. Signal name Pin No. Signal name
put signals put signals
1 NC Output 21 NC Input and output
2 ECMV fill SW.:4th Input 22 COMM_CAN_L_O Input and output
3 ECMV fill SW.:3rd Input 23 NC Input and output
4 232C_RxD Input 24 PWR_CTR_EXT Input
5 Shift lever:4th Input 25 Shift lever:2nd Input
6 Parking brake signal Input 26 Direction lever:N Input
7 ECMV fill SW.:1st Input 27 ECMV fill SW.:F Input
8 NC Output 28 J/S or RH FNR seesaw SW.:N Input
9 NC Output 29 GND_SIG_P
10 NC Input 30 NC Input
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input and output
13 ECMV fill SW.:2nd Input 33 NC Input and output
14 232_TxD Output 34 232C_GND
15 Shift lever:3rd Input 35 Shift lever:1st Input
16 Direction lever:R Input 36 Direction lever:F Input
17 ECMV fill SW.:R Input 37 J/S or RH FNR seesaw SW.:F Input
18 NC Output 38 J/S or RH FNR seesaw SW.:R Input
19 NC Output 39 GND_SIG_P
20 Output speed sensor Input 40 Input speed sensor Input
DEUTSCH-40P(2) [CN-L04]
Input and Input and
Pin No. Signal name Pin No. Signal name
output signals output signals
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 TM power hold relay Output 24 PWR_CTR_KEY Input
5 ECMV:F. clutch Output 25 ECMV:1st clutch Output
6 ECMV:2nd clutch Output 26 ECMV:4th clutch Output
7 NC Output 27 Fan pump EPC Output
8 Indicator with built-in TM cut off SW. Output 28 Fan pump neutral solenoid Output
9 NC Input 29 RESUME/DECEL SW. Input
10 TM cut off SW. Input 30 Kick down SW. Input
11 PWR_IN_BATT Input 31 GND_PWR
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 PWR_OUT_5V_1 Output
15 ECMV:R. clutch Output 35 ECMV:lock up clutch Output
16 ECMV:3rd clutch Output 36 NC Output
17 E.C.S.S. solenoid Output 37 Fan pump reverse solenoid Output
18 Reverse lamp relay Output 38 NC Output
19 SET/ACCEL SW. Input 39 LH brake pedal SW. Input
20 TM cut off position set SW. Input 40 Shift hold SW. Input
WA500-6 67
SEN00713-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
68
SEN00874-02
WA500-6
WA500-6 1
SEN00874-02 10 Structure, function and maintenance standard
2 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Function
No. Function Operation
Selection of travel direction and
1 The travel direction can be changed by operating the directional lever.
neutral
2 Selection of gear speed The gear speed can be changed by operating the gearshift lever.
The gear can be shifted down by pressing the kickdown switch without operating
the gearshift lever. In the manual gear shift mode, the gear is shifted down to the
3 Kickdown 1st only while the transmission is in the forward 2nd. In the auto-shift mode, the
gear is shifted down according to the gear speed and travel speed before the
switch is pressed.
If the hold switch is pressed in the auto-shift mode, the current gear speed is held
4 Hold and is not shifted up even if the travel speed is increased. Even if the travel speed
lowers, the gear is not shifted down.
While the transmission cut-off selector is “ON”, the transmission is set in neutral
5 Transmission cut-off
at the adjusted pressing distance of the brake pedal.
The pressing distance of the brake pedal to set the transmission in neutral with
6 Transmission cut-off set
the transmission cut-off function can be adjusted.
The transmission cut-off function can be turned ON and OFF. While this function
7 Selection of transmission cut-off is “OFF”, the left brake pedal works as the ordinary brake (similarly to the right
brake pedal).
While the parking brake is applied, the transmission is set in neutral. With this
8 Neutralizer function, the machine does not travel while the parking brake is applied, thus sei-
zure of the parking brake is prevented.
While the directional lever is not in “neutral”, the engine does not start even if the
9 Neutral safety starting switch is operated, thus an accident caused by sudden start of the
machine is prevented.
When the machine travels in reverse, the backup lamp and backup buzzer are
10 Alarm
turned ON to warn around the machine.
WA500-6 3
SEN00874-02 10 Structure, function and maintenance standard
Combination switch
Outline
q The directional lever has 3 positions and the gearshift lever switch has 4 positions.The detent mecha-
nism is not installed to each switch but installed to the body of the combination switch. Each switch is
positioned with 2 pins and fixed to the body with 3 screws. If each lever is set in a desired position, the
switch connected by the shaft operates to supply the current to only the circuit of the desired position.
Function
No. Type Operation
1 Directional lever switch Selects the travel direction and neutral.
2 Gearshift lever switch Selects a gear speed.
3 Gearshift lever stopper Prevents the gearshift lever from moving to the 3rd or 4th position during work.
4 Turn signal Turn signal for L.H. and R.H. turns
Returns the turn signal lever automatically to neutral when the steering wheel is
5 Self-cancel
returned after turning to the right or left.
6 Lamp switch Selects the clearance lamp, headlamp, parking lamp, etc.
7 Dimmer switch Selects main beam and low beam.
8 Hazard switch Flashes turn signals to the left and right simultaneously.
9 Hazard pilot lamp Flashes while the hazard lamp flashes.
4 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Operation
q Shaft (2) of directional and gearshift lever (1) of
the combination switch is made one with mag-
net (3). As lever (1) moves, magnet (3)
moves, too.
q Control switch (5) having Hall IC's (4) in it is
installed under magnet (3). Hall IC (4) are
arranged on the board for each position.
q When the directional lever is set in the “F” posi-
tion, magnet (3) comes to directly above Hall
IC (4) of the “F” position of the control switch.
Magnet (3) magnetizes Hall IC (4) through the
clearance and case (6).
q Hall IC (4) is in the magnetism sensor circuit
and it detects the magnetism of magnet (3)
and sends the signal of the “F” position of the
directional lever to the current amplifier cir-
cuit.The current amplifier circuit outputs the
signal to operate the transmission valve.
WA500-6 5
SEN00874-02 10 Structure, function and maintenance standard
Function
1. The neutral safety circuit is employed to
secure safety when the engine is started.
q The engine can not be started while the
directional lever is not in N (Neutral).
q The engine cannot start while the right
FNR selector switch (if equipped) is “ON”
or while the right FNR switch is not in N
(Neutral).
q The engine cannot start while the joystick
steering (if equipped) is “ON” or while
either of the joystick steering lever FNR
switch and joystick steering lever is not in
N (Neutral).
2. The KOMTRAX engine cut circuit is employed
to disable the engine from starting when the
KOMTRAX receives an engine cut command
issued through external operation.
6 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Operation
1. When starting switch is turned to “ON” position q While the right FNR switch (if equipped) is
q If the starting switch is turned to the “ON” used (the right FNR selector switch is
position, terminals B and BR of the start- ON), the current flows from the right FNR
ing switch are closed and the current flows selector switch to the transmission con-
from the battery through the starting troller to enable the controller. At this time,
switch and battery relay coil to the ground if the FNR switch is not in N (Neutral), the
and the contacts of the battery relay are work equipment controller outputs the cut-
closed. As a result, the power is supplied out current and the current flows to the
to each circuit of the machine. lever relay coil, cutting terminal 3 of the
Also, the current flows from terminal ACC lever relay out from terminal 6 of the same
of the starting switch into the engine con- relay.
troller power relay, operating it to provide
the power supply for operation to the 3. When starting switch is turned to “Start” posi-
engine controller, and the engine is ready tion
to start. q If the starting switch is turned to the “Start”
2. Neutral safety circuit position, the current flows through termi-
q If the directional lever is set in the N (Neu- nal B of the starting switch, terminal C of
tral) position, the current flows from con- the same switch, terminal 3 of the
tact (N) of the directional lever through the KOMTRAX engine cut relay, terminal 6 of
exchange relay to the neutral safety relay the same relay, terminal 3 of the neutral
coil, conducting terminal 3 of the neutral safety relay, terminal 5 of the same relay,
safety relay with terminal 5 of the same terminal 3 of the lever relay, and terminal 6
relay. of the same relay to the starting motor to
q While the joystick steering (if equipped) is start the engine.
used, if the joystick steering armrest is q At the same time, the current flows from
tilted forward and the joystick steering terminal C of the starting switch to the
selector switch is turned ON, the current engine controller, where the engine speed
flows from the joystick steering selector and coolant temperature signals are pro-
switch to the transmission controller to cessed to optimize the injection rate.
enable the controller. q While the directional lever is not in N
At this time, if the joystick steering lever (Neutral) or the right FNR switch is not in
FNR switch is not in N (Neutral), the work N (Neutral) (if the right FNR switch is
equipment controller outputs the cutout used) or the joystick steering lever FNR
current and the current flows to the lever switch is in N (Neutral) and the joystick
relay coil, cutting terminal 3 of the lever steering lever is not in N (Neutral) (if the
relay out from terminal 6 of the same joystick steering is used), the neutral
relay. safety relay does not operate and the
If the joystick steering lever is not in N engine does not start.
(Neutral), the work equipment controller q While the right FNR switch is not in N
outputs the cutout current and the current (Neutral) (if the right FNR switch is used)
flows to the lever relay coil, cutting termi- or the joystick steering lever FNR switch is
nal 3 of the lever relay out from terminal 6 in N (Neutral) and the joystick steering
of the same relay. lever is not in N (Neutral) (if the joystick
(If the joystick steering system is installed, steering is used), the lever relay does not
the joystick steering lock switch and joy- operate and the engine does not start.
stick steering selector switch are installed q When the KOMTRAX controller receives
instead of the right FNR selector switch an engine cut command issued through
indicated in the engine starting circuit dia- external operation, it grounds terminal 2 of
gram, and the joystick steering lever FNR the KOMTRAX engine cut relay to operate
switch is installed instead of the right FNR the relay. This cuts out the current from
switch.) terminal 6 of the KOMTRAX engine cut
relay to terminal 3 of the neutral safety
relay, disabling the engine from starting.
WA500-6 7
SEN00874-02 10 Structure, function and maintenance standard
Operation
q If the starting switch is set in the “OFF” posi-
tion, the current of terminal ACC is cut out and
the ACC signal to the engine controller is cut
out accordingly. Then the engine controller
stops the fuel supply to the engine.
As the fuel supply is stopped, the engine slows
down and stops. When the alternator stops
generating electricity, the voltage supply from
the R terminal of the alternator and the current
from the BR terminal of the starting switch are
cut out, the contact of the battery relay opens,
and the power supply provided to various cir-
cuits in the machine is cut out.
q About 10 seconds after the starting switch is
turned OFF, the current from the engine con-
troller to the 2 engine controller cut relays is
cut out. This turns the relay OFF and cuts out
the engine controller operating power supply to
prevent unexpected operation.
8 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Preheating circuit 1
(Automatic preheating system)
Outline
q The automatic preheating system is installed q The preheater pilot lamp on the main monitor
so that the engine will start easily in a cold dis- lights up during preheating. When the preheat-
trict. This system reduces and sets the pre- ing completes, the preheater pilot lamp goes
heating time properly according to the engine out.
coolant temperature when the starting switch is
operated.
q When the starting switch is set in the “ON posi-
tion”, the current flows to the electrical intake
air heater to preheat the intake air.
The engine controller determines the preheat-
ing time according to the coolant temperature
detected by the engine coolant temperature
sensor.
WA500-6 9
SEN00874-02 10 Structure, function and maintenance standard
Operation
q When the starting switch is set in the “ON”
position, the engine controller sends the sig-
nals to operate the heater relay and closes the
contact.
q The current flows from the battery through the
battery relay and heater relay to the electrical
intake air heater for preheating.
q When the preheating completes, the current
from the engine controller to the heater relay is
cut out, and the heater relay contact is opened.
q During preheating, the current flows through
the terminal (BR) of the starting terminal, termi-
nal 1 and terminal 2 of the preheating relay to
the engine controller to energize the coil of the
preheating relay. The preheater pilot lamp on
the main monitor lights up.
a When the preheating completes, the pre-
heater relay turns “OFF” and the pre-
heater pilot lamp goes out.
10 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Operation
q If the starting switch is turned “OFF,” the con-
tacts of the battery relay open, and no current
flows to the parking brake circuit. While the
starting switch is “OFF,” the current does not
flow into parking brake solenoid valve and the
parking brake is kept applied, regardless of the
position of the parking brake switch, whether it
is “ON (applied)” or “OFF (released).”
WA500-6 11
SEN00874-02 10 Structure, function and maintenance standard
Operation
q Since the parking brake selector switch is “ON
(actuate)”, the current flows through the battery
relay, contact 6 of the parking brake selector
switch, contact 5 of the same switch, and park-
ing brake safety relay coil to the chassis
ground, closing the terminal 3 and terminal 5 of
the parking brake safety relay. The current
from the battery relay keeps flowing into the
parking brake relay coil to hold its contacts until
the battery relay contacts open and the current
does not flow into the parking brake circuit any
more.
q At this time, the current does not flow into park-
ing brake solenoid and the parking brake is
kept applied.
q This signal is input to transmission controller to
keep the transmission in neutral and prevent
the parking brake from dragging while the
parking brake is applied.
q After that, if the parking brake switch is turned
“OFF (released)”, the current flows through the
battery relay, parking brake safety relay, con-
tact 4 of the parking brake selector switch, con-
tact 3 of the same switch, emergency brake
switch, and parking brake solenoid to the chas-
sis ground, releasing the parking brake.
12 WA500-6
10 Structure, function and maintenance standard SEN00874-02
2-2. When parking brake switch is turned “OFF (released)” before starting switch is turned “ON“
Operation
q While the starting switch is “OFF”, the current
does not flow into the parking brake safety
relay and its contacts are open. Even if the
starting switch is turned “ON” at this time, the
current does not flow into the parking brake
solenoid. Accordingly, the parking brake is not
released automatically.
WA500-6 13
SEN00874-02 10 Structure, function and maintenance standard
Operation
q If the main brake oil pressure lowers, the con-
tacts of the emergency brake switch installed
to the accumulator open. As a result, the cur-
rent flowing into parking brake solenoid valve
is stopped and the oil in the parking brake cyl-
inder is drained and the parking brake is
applied.
In this case, however, unlike the case where
the parking brake switch is turned “ON (actu-
ate)”, the transmission is not set in neutral
since the parking brake release signal is flow-
ing into the transmission controller.
By the above operation, when the emergency
brake is applied, the braking distance can be
reduced by using the engine as a brake. Also,
even if the emergency brake is applied, the
machine can be moved.
14 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Operation
q When the vehicle stops due to engine trouble,
the oil pressure from the transmission pump to
the parking brake cylinder is cut out, triggering
the parking brake. Under this condition, oil
pressure in the main brake line is held in the
accumulator.
q When the emergency release switch is turned
to “ON (released)”, the buzzer sounds and the
current flows to the emergency parking brake
release solenoid valve, and the oil pressure
held in the accumulator of the main brake line
flows into the parking brake cylinder, releasing
the parking brake.
q The emergency release switch must be in the
“OFF” position during normal operation and
after emergency release is completed.
WA500-6 15
SEN00874-02 10 Structure, function and maintenance standard
Operation
q When the brake pedal is pressed, the contact
of the stop lamp switch is closed to cause the
current to flow to the stop lamp relay coil. This
closes the contact of the relay to complete the
circuit from the fuse through the terminal 5 of
the stop lamp relay, terminal 3 of the same
relay, and right and left stop lamps to the chas-
sis ground, and the right and left stop lamps
light up.
q When the brake pedal is released, the contact
of the stop lamp switch is opened. This opens
the contact of the stop lamp relay, and the stop
lamps go out.
q Because the current flows through the stop
lamp circuit when the battery relay operates,
the stop lamps do not light up when the starting
switch is in the “OFF” position.
16 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Operation
q Because the current flows through the backup 3. When the joystick steering is used
lamp circuit when the battery relay operates, When the right FNR switch is used and even if
the backup lamps do not light up and the the directional lever is in N (Neutral), turning
backup buzzer does not sound when the start- the joystick steering lever FNR switch to R
ing switch is in the “OFF” position. causes the transmission controller to send the
signal to operate the backup lamp relay. The
1. When the directional lever is in the R position right and left backup lamps light up and the
When the directional lever is turned to the R backup buzzer sounds.
position, the transmission controller sends a
signal to the backup lamp relay to open its con-
tact. This completes the circuit from the fuse
through the terminal 5 of the backup lamp
relay, terminal 3 of the same relay, and right
and left backup lamps to the chassis ground,
and the right and left backup lamps light up. At
the same time, the backup buzzer sounds.
2. When the right FNR switch is used
Even if the directional lever is in N (Neutral),
turning the right FNR switch to R causes the
transmission controller to send the signal to
operate the backup lamp relay. The right and
left backup lamps light up and the backup
buzzer sounds.
WA500-6 17
SEN00874-02 10 Structure, function and maintenance standard
Operation
q Because the current flows through the small 2. When the lighting switch is in the Head position
lamp and head lamp circuits when the battery When the lighting switch is turned to the Head
relay operates, the small and head lamps do position, the current flows through the switch
not light up when the starting switch is in the and fuse to the small lamp and head lamp cir-
“OFF” position. cuits. The current flows from the head lamp
through the dimmer switch (Hi/Lo selector
1. When the lighting switch is in the Small posi- switch) to the chassis ground. The high beam
tion or low beam selected with the dimmer switch
When the lighting switch is turned to the Small lights up. The high beam signal is input to the
position, the current flows through the switch main monitor and turns on the high beam pilot
and fuse to the front, rear, right, and left small lamp on the main monitor.
lamps, and the lamps light up. The small lamp
signal is input to the main monitor and turns
the main monitor night lamp on. The circuit
supplies the current in the small lamp circuit to
the working lamp switch, prohibiting the work-
ing lamp from lighting up when the small lamps
are off.
18 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Operation
q The current is supplied to the front and rear
working lamp switches from the small lamp cir-
cuit.
When the working lamp switch is turned “ON”,
the working lamp relay operates to close the
contact. The current flows through the fuse,
working lamp relay, and working lamp to the
chassis ground, and the working lamp lights
up.
At the same time, the indicator in the working
lamp switch lights up.
WA500-6 19
SEN00874-02 10 Structure, function and maintenance standard
Horn circuit 1
Operation
q Because the current flows through the horn cir-
cuit when the battery relay operates, the horn
does not sound when the starting switch is in
the “OFF” position.
20 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Operation
Because the current flows through the wiper and 3) When the front wiper switch is in the INT
window washer circuits when the battery relay (Intermittent) position
operates, the wiper and window washer do not The current flows through the fuse, terminal 7
operate when the starting switch is in the “OFF” of the front wiper switch, and terminal 2 of the
position. When the starting switch is turned “OFF” same switch to the wiper relay, and the relay
during operation, the operation stops. contact closes. Then the current flows
through the fuse, wiper relay, terminal 3 of the
1. Front wiper circuit front wiper switch, and terminal 5 of the same
1) When the front wiper switch is in the Lo posi- switch to the front wiper motor (Lo), and the
tion wiper operates at the low speed. The wiper
The current flows through the fuse, terminal relay repeats the timer-controlled operation
7 of the front wiper switch, and terminal 5 of where wiper makes reciprocating motions at
the same switch to the front wiper motor intervals of 4 – 6 seconds.
(Lo), and the wiper operates at the low 4) When the washer switch is in the “ON” posi-
speed. tion
2) When the front wiper switch is in the Hi posi- The current flows through the fuse and front
tion wiper switch to the washer motor, and the
The current flows through the fuse, terminal washer operates. At the same time, the cur-
7 of the front wiper switch, and terminal 4 of rent flows to the wiper relay and operates
the same switch to the front wiper motor (Hi), the wiper 0.2 – 0.8 seconds after the washer
and the wiper operates at the high speed. switch is turned “ON”.
The wiper relay moves the wiper 2 to 4 times
after the washer switch is turned “OFF”. This
operation occurs when the washer switch is
turned “OFF” after it has been “ON” while the
wiper makes the reciprocating motion more
than once.
WA500-6 21
SEN00874-02 10 Structure, function and maintenance standard
22 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Relay
1. Case 2. Base
1. Case 2. Base
WA500-6 23
SEN00874-02 10 Structure, function and maintenance standard
Sensor 1
Input shaft speed sensor
Output shaft speed sensor
1. Magnet 3. Harness
2. Locknut 4. Connector
Function
q The input shaft speed sensor is installed on the
transmission unit input shaft and the output
shaft speed sensor is installed in the output
gear section at the transmission unit. Those
sensors emit pulse signals according to the
gear rotation signal, which are detected by the
transmission controller.
q Signals are converted from pulse to the num-
ber of rotation (rpm) in the transmission con-
troller, transmitted to the machine monitor over
the network. The rpm is then converted into
travel speed in the machine monitor for display.
24 WA500-6
10 Structure, function and maintenance standard SEN00874-02
1. Sensor
2. Lead wire
3. Connector
Function
q Installed to the brake pilot circuit and detecting
brake operating pressure, this sensor is used
to set brake pressure for the transmission cut-
off function and to operate the function.
a The brake pressure of this sensor changes
when either right or left brake pedal is pressed.
WA500-6 25
SEN00874-02 10 Structure, function and maintenance standard
1. Thermistor
2. Plug
3. Harness
4. Connector
Function
q The oil temperature sensors convert changes
in temperature into changes in thermistor
resistance, and each controller detects temper-
atures.
q Transmission oil temperature sensor detects
the internal temperature of transmission case.
The temperature data is used by transmission
controller to select the temperature table of
electronic modulation so as to control modula-
tion best matched to the oil temperature.
q Data from torque converter oil temperature
sensor and hydraulic oil temperature sensor is
detected by the machine monitor and indicated
to the gauges. At the same time, the data is
transmitted to the transmission controller via
network and used as the cooling fan control
data.
q Axle oil temperature sensor detects the inter-
nal oil temperature of rear axle with the moni-
tor, and outputs a caution signal when the
temperature rises to a high level.
26 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Function
q These switches are installed to the knob of the
lift arm control lever. Switch A (1) works as the
kick-down switch and switch B (4) works as the
hold switch.
q These switches are installed to the knob of the
lift arm control lever when load meter (if
equipped) is installed. Switch A works as the
cancel switch and switch B works as the subto-
tal switch.
q Both of switch A (1) and switch B (4) are of
automatic-reset type, that is, their contacts are
closed only while they are pressed.
WA500-6 27
SEN00874-02 10 Structure, function and maintenance standard
Function
q Directional switch is held at a selected posi-
tion. Transmission controller shifts gear
according to the signal from the directional
switch.
q Shift-up/-down switch selects circuit only while
the switch is being depressed, and the trans-
mission controller uses this signal for gear
shifting operation accordingly.
q The N.C. (normally close) side of the shift up/
down switch is not connected to the controller.
q Horn switch operates the relay and sounds the
horn while it is being depressed.
28 WA500-6
10 Structure, function and maintenance standard SEN00874-02
Function
q Directional switch is held at a selected posi-
tion. Transmission controller shifts gear
according to the signal from the directional
switch.
WA500-6 29
SEN00874-02 10 Structure, function and maintenance standard
1. Oil seal
2. Case
3. Resistor assembly
4. Brush
5. Shaft
6. Connector
Function
q The lift arm angle sensor is installed to the
front frame. When the lift arm angle changes,
the shaft receives the sliding resistance
through the link installed to the lift arm and the
lift arm angle is detected from that sliding resis-
tance.
The angle sensor is installed to a machine
installed with a load meter or electric work
equipment lever.
30 WA500-6
10 Structure, function and maintenance standard SEN00874-02
1. Sensor 2. Connector
Function Operation
q Installed to the inlet port circuit for the control q When oil pressure led from the pressure input
valve, these sensors convert pump discharge port applies pressure to the diaphragm of oil
pressure to voltage and transmit to the gover- pressure sensor, the diaphragm is deformed
nor pump controller. from deflection.
q Gauge layer is installed to the opposite of the
diaphragm. Deflection of the diaphragm is con-
verted into output voltage by the resistance of
the gauge layer and is sent to the amplifier.
q After amplifying the voltage, the amplifier
transmits the voltage to the governor controller.
q Relational expression of pressure P (MPa {kg/
cm2}) and output voltage (V)
WA500-6 31
SEN00874-02 10 Structure, function and maintenance standard
Function
q The fuel level sensor is installed to the side of
the fuel tank. The float moves up and down
according to the fuel level.
The float moves the variable resistor through
the arm. The voltage signal is sent to the
machine monitor to indicate the fuel level.
Also, when the machine monitor indicator
reaches a specified position, caution lamp is lit.
32 WA500-6
10 Structure, function and maintenance standard SEN00874-02
1. Case
2. Tube
3. Connector
Function
q When the parking brake is released, oil pres-
sure is fed to the brake piston. The oil pressure
operates the pressure switch to turn out the
parking brake pilot lamp on the machine moni-
tor.
q When the foot brake is stepped on and the
brake operating pressure is generated, the
pressure switch contact is closed, the relay is
operated and stop lamp lights up.
WA500-6 33
SEN00874-02 10 Structure, function and maintenance standard
1. Indicator
2. Spring
3. Adapter
Function
q The air cleaner clogging sensor is installed to
the air cleaner outlet. If the air cleaner is
clogged and the pressure reaches the speci-
fied level (negative pressure), caution lamp on
the machine monitor lights up to output a warn-
ing.
34 WA500-6
10 Structure, function and maintenance standard SEN00874-02
1. Body Function
2. Tube q The clogging sensor is installed to the filter
3. Connector section. If the filter is clogged and the pressure
difference between the lower and higher sides
A: Take-out port on low pressure side reaches a specified level, the switch turns
B: Take-out port on high pressure side OFF, and the maintenance caution lamp lights
up. At the same time, a message appears to
the character display to warn on abnormal situ-
ation.
WA500-6 35
SEN00874-02 10 Structure, function and maintenance standard
1. Body 3. Tube
2. Shaft 4. Connector
Function
q The steering oil pressure sensor switch detects
operation of diverter valve spool, which is
tripped to operate when the steering oil pres-
sure drops.
q If the steering oil pressure drops and the spool
operates, the switch piston is turned OFF and
the circuit opens.
36 WA500-6
10 Structure, function and maintenance standard SEN00874-02
1. Stopper 4. Plug
2. Float 5. Tube
3. Sensor 6. Connector
Function
q This sensor is installed on the coolant sub-
tank. If the coolant level lowers below the
specified level, the float lowers and the switch
is turned “OFF” and the caution lamp on the
machine monitor lights up for warning.
WA500-6 37
SEN00874-02 10 Structure, function and maintenance standard
1. Case
2. Tube
3. Connector
Function
q If the brake accumulator oil pressure lowers,
the contact becomes OPEN, and the caution
lamp lights up on the machine monitor to warn
of abnormality.
38 WA500-6
10 Structure, function and maintenance standard SEN00874-02
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
q The battery electrolyte level sensor is installed
to the battery. If the battery electrolyte level
lowers below the specified level, the sensor tip
is exposed to air and a signal of voltage
change is generated. The signal is sent to the
machine monitor to warn of abnormal situation.
WA500-6 39
SEN00874-02 10 Structure, function and maintenance standard
1. Pedal
2. Connector
3. Sensor
Function
q This sensor is installed on the surface of the Output characteristics
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pedal pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the sensor is output in
variable voltage from No. 2 pin.
40 WA500-6
10 Structure, function and maintenance standard SEN00874-02
1. Case
2. Tube
3. Connector
Function
q When the brake accumulator pressure lowers,
the switch contact opens. Circuit between the
parking brake switch and parking brake sole-
noid is cut off, and the parking brake is tripped
to operate.
WA500-6 41
SEN00874-02 10 Structure, function and maintenance standard
KOMTRAX system 1
(if equipped)
q The KOMTRAX terminal sends various information on the machine by a wireless communication. The
KOMTRAX operator refers to this information in the office, and various services can be provided for the
customer.
42 WA500-6
10 Structure, function and maintenance standard SEN00874-02
KOMTRAX terminal
Model name: TC301
The KOMTRAX system uses satellite communication technology.
Outline
q The KOMTRAX terminal can send information q Use of KOMTRAX terminal must be limited for
via wireless communication antenna, acquiring the countries in which such communication is
various information of the machine from the allowed.
network signal in the machine and the input q There are the LED lamp and the 7-segment
signal. Also, the controller incorporates CPU indicator lamp in the display area, and these
(Central Processing Unit) and provide the wire- lamps are used for the testing and the trouble-
less communication function and the GPS shooting.
function. q The information of the LED lamp and the 7-
segment indicator lamp can be checked on the
monitor panel by EMMS.
WA500-6 43
SEN00874-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
44
SEN00724-05
WA500-6
WA500-6 1
SEN00724-05 20 Standard value table
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the RPM
idle-up/down selector switch.
2 WA500-6
20 Standard value table SEN00724-05
— —
HOLD
• Engine speed: Low idle (*1)
LOWER o N Max. 18.6 Max. 28.4
• Hydraulic oil temperature: Within
FLOAT {kg} {Max. 1.9} {Max. 2.9}
Work equipment control lever
operating range
Max. 10.8 Max. 16.2
FLOAT o HOLD
{Max. 1.1} {Max. 1.7}
Max. 10.8 Max. 16.2
HOLD o DUMP
{Max. 1.1} {Max. 1.7}
HOLD o TILT Max. 10.8 Max. 16.2
Bucket
(*2) {Max. 1.1} {Max. 1.7}
Max. 10.8 Max. 16.2
TILT o HOLD
{Max. 1.1} {Max. 1.7}
HOLD io
40 ± 10 40 ± 15
RAISE (*2)
HOLD io
Lift arm 40 ± 10 40 ± 15
LOWER (*2)
• Engine speed: Low idle (*1)
Stroke
HOLD io
• Hydraulic oil temperature: Within mm 45 ± 10 45 ± 15
FLOAT
operating range
HOLD o DUMP 40 ± 10 40 ± 15
Bucket
HOLD o TILT
40 ± 10 40 ± 15
(*2)
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the
RPM idle-up/down selector switch.
*2: The value shows the value before the detent.
WA500-6 3
SEN00724-05 20 Standard value table
• Engine stopped
Play mm Max. 40 50 – 100
• Machine facing straight to front
• Flat, level, straight, dry, and
paved road N 9.8 ± 2.0
Steering wheel
A Max. 2.5 —
Fitting of wheel lock ring a For measuring posture, see Fig.
C at end of this section
Tire
B mm Max. 4.0 —
• Tire inflation pressure: Specified
Clearance of wheel lock pressure
C 2 – 15 —
ring
4 WA500-6
20 Standard value table SEN00724-05
range
• Torque converter oil P-mode 2,100 ± 100 2,100 ± 200
Hydraulic stall temperature: Within rpm
operating range E-mode 2,000 ± 100 2,000 ± 200
• Hydraulic oil tempera-
ture: Within operating
P-mode 1,800 ± 100 1,800 ± 300
Torque converter stall + range
hydraulic stall
E-mode 1,765 ± 100 1,765 ± 300
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the RPM idle-up/
down selector switch.
WA500-6 5
SEN00724-05 20 Standard value table
{60 (+10/–5)}
idle (*1) lamp goes out
MPa
• Hydraulic oil • Point where oil
{kg/cm2}
temperature: pressure is 9.8
Within operat- 9.8 (+0.98/0)
Charge cut-out pressure going up and (+1.47/–0.49)
ing range {100 (+10/0)}
then starts to {100 (+15/–5)}
go down
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the
RPM idle-up/down selector switch.
6 WA500-6
20 Standard value table SEN00724-05
WA500-6 7
SEN00724-05 20 Standard value table
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the
RPM idle-up/down selector switch.
8 WA500-6
20 Standard value table SEN00724-05
*1: Denotes the low idle speed when the engine speed was decreased to the minimum speed with the RPM
idle-up/down selector switch.
WA500-6 9
SEN00724-05 20 Standard value table
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
10 WA500-6
20 Standard value table SEN00724-05
a Fig. G a Fig. K
a Fig. H
a Fig. J
WA500-6 11
SEN00724-05
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
12
SEN00725-08
WA500-6
WA500-6 1
SEN00725-08 30 Testing and adjusting
2 WA500-6
30 Testing and adjusting SEN00725-08
Symbol
Testing and adjusting
Q'ty
Part Number Name Remarks
item
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299 °C
temperature
Commercially
Adjusting valve clearance C Clearance gauge 1
available
1 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1330 Adapter 1
pressure 2
6261-71-6150 Gasket 1
Measuring blow-by pres-
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
sure
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
F Pressure gauge:
pressure 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1.0 MPa {10 kg/cm2}
Measuring intake air –101 – 200 kPa
G 799-201-2202 Boost gauge kit 1
(boost) pressure {–760 – 1,500 mmHg}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
Testing fuel pressure H 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1.0 MPa {10 kg/cm2}
3 795-471-1450 Adapter 1 8 x 1.25 mm o R1/8
1 6151-51-8490 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 5 mm x 2 – 3 m
available
Testing return rate and Commercially
J 4 Hose 1 15 mm x 2 – 3 m
leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring directional lever
(Steering wheel specifica- K 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
tion)
WA500-6 3
SEN00725-08 30 Testing and adjusting
Symbol
Testing and adjusting
Q'ty
Part Number Name Remarks
item
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting Pressure gauge:
L 790-261-1204 Digital hydraulic tester 1
power train oil pressure 60 MPa {600 kg/cm2}
799-101-5220 Nipple 1 10 x 1.25 mm
2 Pressure gauge:
07002-11023 O-ring 1
1.0 MPa {10 kg/cm2}
Method of moving machine
when transmission valve is M 794-423-1190 Plug 1 20 x 1.5 mm
broken
Testing and adjusting
N 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
steering wheel
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Testing steering oil pres-
Q
sure 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3200 Adapter 1 Size 03
Differential pressure
4 799-401-2701 1
gauge
1 799-205-1100 Tachometer kit 1 Digital indication: 6 – 99999.9 rpm
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
2 {25, 60, 400, 600 kg/cm2}
Testing hydraulic drive fan R Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
4 799-401-3500 Adapter 1 Size 06
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
Bleeding air from hydrau- 60 MPa {600 kg/cm2}
S
lic drive fan circuit
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3500 Adapter 1 Size 06
4 790-261-1130 Coupling 1
4 WA500-6
30 Testing and adjusting SEN00725-08
Symbol
Testing and adjusting
Q'ty
Part Number Name Remarks
item
— 792-610-1703 Gas charging tool 1
A 1 792-610-2310 Extension 1
2 792-610-1260 Nipple (for Japan) 1 Size: W22-14 x W23-14
B 792-610-1270 Hose 1
C 792-610-2410 Bushing 1
Testing of accumulator D 792-610-1400 Regulator 1
nitrogen gas pressure and 792-610-1310 Nipple (for Russia) 1 GOST
procedure for charging
792-610-1320 Nipple (for USA) 1 CGA No.351
accumulator with nitrogen
gas 792-610-1330 Nipple (for USA) 1 ASA B-571-1965
E DIN 477-1963
792-610-1350 Nipple (for Germany) 1 NEN 3268-1966
SIS-SMS2235/2238
792-610-1360 Nipple (for UK) 1 BS 341Part1-1962
Commercially
F Nitrogen gas cylinder 1
available
1 793-520-1821 Nipple 1
Testing wheel brake oil 2 793-520-1810 Joint 1
U
pressure 3 385-10178481 Bleeder screw 1
4 793-520-1831 Gauge assembly 1 G1/4 o R1/8
Measuring wear of wheel Commercially
V Slide calipers 1
brake disc available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
WA500-6 5
SEN00725-08 30 Testing and adjusting
Symbol
Testing and adjusting
Q'ty
Part Number Name Remarks
item
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Measuring work equip-
ZA
ment oil pressure 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Differential pressure
3 799-401-2701 1
gauge
4 799-401-3200 Adapter 1 Size 03
Measuring coolant temper-
— 799-101-1502 Digital thermometer 1
ature and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work equip- Commercially
— Stopwatch 1
ment speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting of the control-
lers, sensors, actuators, and wiring harnesses, see Troubleshooting, T-branch box and T-branch table.
6 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 7
SEN00725-08 30 Testing and adjusting
8 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 9
SEN00725-08 30 Testing and adjusting
10 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 11
SEN00725-08 30 Testing and adjusting
12 WA500-6
30 Testing and adjusting SEN00725-08
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
a Adjusting tool for valve clearance nut (4).
a After setting the No. 1 cylinder to the com-
Symbol Part No. Part name pression top dead center, adjust the valve
Commercially clearance of the No. 1 cylinder.
C Clearance gauge
available
4. Insert clearance gauge C in the clearance
1. Remove 6 cylinder head covers (1), referring between rocker arm (5) and crosshead (6) and
to Disassembly and assembly, "Removal and adjust the valve clearance with adjustment
installation of cylinder head assembly". screw (3).
a Shape of the engine shown in this figure is a With the clearance gauge inserted, turn
not identical with that of SAA6D140E-5 the adjustment screw so that clearance
engine installed on WA500-6. gauge can move with a light force.
a Valve clearance
Intake valve: 0.35 mm,
Exhaust valve: 0.57 mm
WA500-6 13
SEN00725-08 30 Testing and adjusting
14 WA500-6
30 Testing and adjusting SEN00725-08
6. Set the mode to the no injection cranking oper- a Install the injector wiring harness accord-
ation, referring to the service mode of "Special ing to the following procedure.
functions of machine monitor (EMMS)". 1) Install the injector wiring harness to
k Be sure to set no injection cranking the rocker arm housing and fix the
mode. Otherwise engine may start and connector side with the plate.
this may create a dangerous condition. 2) Fix the clamp in the intermediate
position with the clip.
7. Rotate the engine cranking with the starting 3) Tighten the nut on the injector side.
motor and measure the compression pressure. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a Read the pressure gauge pointer when it 4) Secure the clamp and spacer with the
is stabilized. bolt.
3 Rocker arm assembly mounting
8. After finishing testing, remove the testing tools bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
and return the removed parts. a Adjust the valve clearance, referring to
a Install the injector and fuel high-pressure “Adjusting valve clearance.“
tube according to the following procedure. 3 Cylinder head cover mounting bolt:
1) Push in injector (11) with the hand to 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14)
temporarily.
2 Spherical portion of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel
high-pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
WA500-6 15
SEN00725-08 30 Testing and adjusting
a Blow-by pressure measurement tools 8. While pressing the brake pedal, set the direc-
Symbol Part No. Part Name tional lever, joystick steering directional switch
or right directional switch to the F (forward) or
E 799-201-1504 Blow-by checker
R (reverse) position.
k Keep pressing the brake pedal
a Measure the blow-by pressure under the fol-
securely.
lowing condition.
q Engine coolant temperature:
9. Press the accelerator pedal gradually to the
Within operating range
high idle. While running the engine at high idle,
q Hydraulic oil temperature:
stall the torque converter and measure the
Within operating range
blow-by pressure.
q Torque converter oil temperature:
a Do not keep stalling the torque converter
Within operating range
for more than 20 seconds. Take care that
the torque converter oil temperature will
1. Stop the engine. Install nozzle [1] and hose [2]
not exceed 120°C.
of blow-by checker E to blow-by hose (1) and
a Normally, the blow-by pressure should be
connect them to gauge [3].
measured while the engine is operated at
the rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
measure while the engine is running at
high idle. The value obtained in this case
is about 80% of the blow-by pressure at
the rated output.
a Precaution for measuring blow-by pres-
sure
The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
2. Start the engine and increase the engine cool- increase of oil consumption, bad exhaust
ant temperature to the operating range. gas color, deterioration of oil, high deterio-
ration speed of oil, etc. which are related
3. Drain oil in the hose while running the engine to the abnormal blow-by pressure.
at medium speed or above.
a Insert approximately half of the gauge and
hose connection to the hose and then
repeat opening the self-seal of the hose to
drain oil.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
16 WA500-6
30 Testing and adjusting SEN00725-08
Measuring engine oil pressure 1 4. Start the engine and raise the coolant tempera-
a Engine oil pressure measurement tools ture to the operating range.
Symbol Part Number Part name 5. Measure the engine oil pressure when the
799-101-5002 Hydraulic tester engine is run at low idle or high idle speed.
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
WA500-6 17
SEN00725-08 30 Testing and adjusting
Measuring intake air (boost) 3. Remove intake air (boost) temperature pickup
pressure 1 plug (3) (R1/8) in the rear side of the air intake
manifold.
a Measuring instruments for intake air (boost)
pressure
Symbol Part No. Part Name
G 799-201-2202 Boost gauge kit
18 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 19
SEN00725-08 30 Testing and adjusting
20 WA500-6
30 Testing and adjusting SEN00725-08
Testing fuel pressure 1 4. Run the engine at high idle and measure the
a Testing tools for fuel pressure fuel pressure.
a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
H High idle
2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm2}
3 795-471-1450 Adapter
WA500-6 21
SEN00725-08 30 Testing and adjusting
a Testing tools for fuel return rate and leakage 1. Preparation work
1) Open the engine right side cover.
Symbol Part No. Part name 2) Remove tube (3) between common rail (1)
1 6151-51-8490 Spacer and supply pump (2).
3) Insert spacer J1 to supply pump (2) side
2 6206-71-1770 Joint
and tighten the currently removed joint
Commercially bolt again.
3 Hose
available a Connect the return pipe to the fuel
J 4
Commercially
Hose
tank again, too.
available a Be sure to provide a gasket to both
Commercially ends of the spacer.
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
22 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 23
SEN00725-08 30 Testing and adjusting
24 WA500-6
30 Testing and adjusting SEN00725-08
a If fuel is used up or if a fuel circuit part is a Do not add fuel to fuel main filter (2) from
removed and installed, bleed air from the fuel outside.
circuit according to the following procedure.
WA500-6 25
SEN00725-08 30 Testing and adjusting
3. Install fuel pre-filter (1) to filter head. 6. Loosen air bleeder (6) of the fuel supply pump
a Coat the packing surface of the fuel pre-fil- and operate priming pump (4) 90 – 100 times.
ter side with small amount of engine oil. a Operate the priming pump until the fuel
a Tighten the packing surface of the fuel flows out of the air bleeder and tighten the
pre-filter by 3/4 turns after confirming it is air bleeder. Then, operate the priming
contacted against the sealing surface of pump several times more until it becomes
the filter head. heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
26 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 27
SEN00725-08 30 Testing and adjusting
28 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 29
SEN00725-08 30 Testing and adjusting
Testing and adjusting alternator 6. Using 2 mounting bolts, install belt cover (1).
belt tension 1 a Check for breakage of the pulleys, wear of
the V-grooves, contact of V belts and V-
Testing
grooves, and contact of the belt covers
1. Open the engine right side cover. and rotating parts.
a V belt must be replaced with a new one if
2. Using a finger, press the belt at midpoint it is stretched out and its adjustment allow-
between the alternator pulley and water pump ance is lost or when cut or crack is
pulley to check deflection (a). observed on it.
a Pressing force: a Whenever a V belt was replaced, test and
Approx. 98 N {Approx. 10 kg} adjust it again after operating an hour.
a Deflection (a): 13 – 16 mm a After tightening the bolt, make sure the
belt tension is normal following the proce-
dure described above.
Adjusting
a If the deflection of the belt is abnormal, adjust it 7. Restore the original state after the testing and
according to the following procedure. adjusting.
1. Remove 2 mounting bolts and then remove
belt cover (1).
a Remove the belt cover only when the belt
is replaced.
30 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 31
SEN00725-08 30 Testing and adjusting
32 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 33
SEN00725-08 30 Testing and adjusting
34 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 35
SEN00725-08 30 Testing and adjusting
a Testing and adjusting instruments for power 1. Remove rear frame left side cover (12) and
train oil pressure right side cover (13).
Symbol Part Number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
36 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 37
SEN00725-08 30 Testing and adjusting
2. Measuring torque converter relief pressure 4) While running the engine at high idle,
(inlet pressure) measure torque converter relief pressure
1) Remove torque converter relief pressure (inlet pressure).
(inlet pressure) pickup plug (2) (10 x 1.25
mm).
k Prepare an oil pan since oil flows
out as the pickup plug is removed.
38 WA500-6
30 Testing and adjusting SEN00725-08
3. Measuring torque converter outlet pressure 5) Remove the measurement tool after the
1) Remove torque converter outlet pressure measurement, and make sure that the
pickup plug (3) (10 x 1.25 mm). machine is back to normal condition.
WA500-6 39
SEN00725-08 30 Testing and adjusting
4. Measuring lockup clutch pressure (Lockup 8) Measure the lockup clutch oil pressure as
clutch specification) the lockup pilot lamp came on while travel-
k This measurement is done in the travel- ing is continued with the engine at high
ing condition. Reasonable care, there- idle.
f o r e , m u s t b e pa i d t o s a f e t y o f
surrounding area.
1) Remove lockup clutch pressure pickup
plug (4) (10 x 1.25 mm).
40 WA500-6
30 Testing and adjusting SEN00725-08
5. Measuring F (forward) clutch pressure 8) Measure the F (forward) clutch oil pres-
1) Remove F (forward) clutch oil pressure sure when the engine is run at high idle.
pickup plug (5) (10 x 1.25 mm).
WA500-6 41
SEN00725-08 30 Testing and adjusting
6. Measuring R (reverse) clutch pressure 8) Measure the R (reverse) clutch oil pres-
1) Remove R (reverse) clutch oil pressure sure when the engine is run at high idle.
pickup plug (6) (10 x 1.25 mm).
42 WA500-6
30 Testing and adjusting SEN00725-08
7. Measuring 1st clutch pressure 3) Set the transmission auto shift and man-
1) Remove 1st clutch oil pressure pickup ual shift selector switch in the MANUAL
plug (7) (10 x 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) Set the gear shift lever to the 1st speed
while maintaining the directional lever, joy-
stick steering directional switch or right
directional switch at the N (Neutral) posi-
tion.
7) Run the engine at low idle and while
pressing the brake pedal, set the direc-
tional lever, joystick steering directional
switch or right directional switch to the F
(forward) or R (reverse) position once and
then return it to N (Neutral) again.
k Keep pressing the brake pedal
2) Connect nipple L2 and oil pressure gauge
[1] in hydraulic tester L1.
securely.
a Use the oil pressure gauge with
a Above operation is needed because
capacity 6.0 MPa {60 kg/cm2}.
moving the gear shift lever does not
change the gear speed if the direc-
tional lever, joystick steering switch or
right directional switch is set at the N
(neutral) position.
8) While running the engine at high idle,
measure the 1st clutch oil pressure.
WA500-6 43
SEN00725-08 30 Testing and adjusting
8. Measuring 2nd clutch pressure 3) Set the transmission auto shift and man-
1) Remove 2nd clutch oil pressure pickup ual shift selector switch in the MANUAL
plug (8) (10 x 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) Set the gear shift lever to the 2nd speed
while maintaining the directional lever, joy-
stick steering directional switch or right
directional switch at the N (Neutral) posi-
tion.
7) Run the engine at low idle and while
pressing the brake pedal, set the direc-
tional lever, joystick steering directional
switch or right directional switch to the F
(forward) or R (reverse) position once and
then return it to N (Neutral) again.
2) Connect nipple L2 and oil pressure gauge k Keep pressing the brake pedal
44 WA500-6
30 Testing and adjusting SEN00725-08
9. Measuring 3rd clutch pressure 3) Set the transmission auto shift and man-
1) Remove 3rd clutch oil pressure pickup ual shift selector switch in the MANUAL
plug (9) (10 x 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) Set the gear shift lever to the 3rd speed
while keeping the directional lever, joystick
steering directional switch or right direc-
tional switch at the N (Neutral) position.
7) Run the engine at low idle and while
pressing the brake pedal, set the direc-
tional lever, joystick steering directional
switch or right directional switch to the F
(forward) or R (reverse) position once and
then return it to N (Neutral) again.
k Keep pressing the brake pedal
securely.
2) Connect nipple L2 and oil pressure gauge
a Above operation is needed because
[1] in hydraulic tester L1.
moving the gear shift lever does not
a Use the oil pressure gauge with
change the gear speed if the direc-
capacity 6.0 MPa {60 kg/cm2}.
tional lever, joystick steering switch or
right directional switch is set at the N
(neutral) position.
8) While running the engine at high idle,
measure the 3rd clutch oil pressure.
WA500-6 45
SEN00725-08 30 Testing and adjusting
10. Measuring 4th clutch pressure 3) Set the transmission auto shift and man-
1) Remove 4th clutch oil pressure pickup ual shift selector switch in the MANUAL
plug (10) (10 x 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) Set the gear shift lever to the 4th speed
while keeping the directional lever, joystick
steering directional switch or right direc-
tional switch at the N (Neutral) position.
7) Run the engine at low idle and while
pressing the brake pedal, set the direc-
tional lever, joystick steering directional
switch or right directional switch to the F
(forward) or R (reverse) position once and
then return it to N (Neutral) again.
k Keep pressing the brake pedal
46 WA500-6
30 Testing and adjusting SEN00725-08
11. Measuring lubrication pressure 5) Remove the measurement tool after the
1) Remove lubrication pressure pickup plug measurement, and make sure that the
(11) (10 x 1.25 mm). machine is back to normal condition.
Adjusting
1. Adjusting transmission main relief valve
k Stop the engine before starting adjust-
ment of the transmission main relief
valve.
a If the transmission main relief pressure is
out of the specified range, adjust it accord-
ing to the following procedure.
1) Remove plug (13) from transmission and
torque converter relief valve (12).
WA500-6 47
SEN00725-08 30 Testing and adjusting
Flushing procedure for torque 3) Loosen hexagonal portion (a) of two trans-
converter and transmission mission oil filter cases (2) to remove the
cases.
hydraulic circuit 1 a After removing the transmission oil fil-
a Metal chips and dirt in the torque converter and ter case, clean inside of the case as
transmission hydraulic circuit shorten the lives well as removed parts other than the
of the torque converter and transmission and filter.
can cause internal breakage. Accordingly, 4) Remove 2 filter elements (4) and replace
flush the hydraulic circuit to remove the metal them with 2 flushing elements (424-16-
chips and dirt. 11140).
5) Install 2 transmission oil filter cases (2).
1. Flush the hydraulic circuit in the following 3 Hexagonal portion (a) of transmis-
cases. sion oil filter case:
1) When metal chips are circulated in the 58.8 – 78.5 Nm {6 – 8 kgm}
hydraulic circuit because of damage of the 3 Drain plug:
torque converter, transmission, or another 49 – 58.8 Nm {5 – 6 kgm}
hydraulic device.
2) When the torque converter or transmis-
sion is overhauled or repaired.
48 WA500-6
30 Testing and adjusting SEN00725-08
3. Fill the transmission case with oil. 6. Replace the transmission last chance filter.
Add oil through oil filler (5) to the specified 1) Remove cover (6) on the left side of the
level. Run the engine to circulate the oil rear frame.
through the system. Then, check the oil level
again.
5 Transmission case:
76 l (Refill capacity)
WA500-6 49
SEN00725-08 30 Testing and adjusting
50 WA500-6
30 Testing and adjusting SEN00725-08
a Device for moving machine when transmission k When working while the oil temperature is
valve is broken still high, take care not to burn your body.
Symbol Part Number Part name
1. Remove cover (1) on the left side of the rear
M 794-423-1190 Plug frame.
a Remove mud and dirt from around the
a Even if the machine became not movable ECMV.
because of a failure on the transmission valve
portions (electrical system, solenoid valve,
spool, etc.), install plug M to enable moving the
machine.
k Installing plug M to the ECMV is the means
for moving the machine from a dangerous
job site to a safe place for repair. This
approach should be resorted only when the
machine is not movable at any gear speed
because of a failure on the transmission
control valve and should not be employed
for any other purpose.
k When moving the machine by this method,
observe the procedure and take care of
safety.
k Lower the work equipment to the ground
fully, apply the parking brake, and put
chocks under the tires so that the machine
will not move.
k When applying this means, stop the engine.
WA500-6 51
SEN00725-08 30 Testing and adjusting
2. Disconnect the connector of the 2nd ECMV 4. Press the brake pedal securely.
and the connector of the F or R ECMV.
q F ECMV (Forward) connector: 5. Start the engine and release the parking brake
F.SW and F.PS gradually to start and move the machine.
q R ECMV (Reverse) connector: a If the parking brake cannot be released
R.SW and R.PS because of a trouble in the electrical sys-
q 2nd ECMV (2nd speed) connector: tem, see “Method of releasing parking
2.SW and 2.PS brake manually“.
a Select either F ECMV or R ECMV k Remove the chocks.
depending on the machine moving direc- k If the engine is started, the transmis-
tion (Forward or Reverse) sion is engaged and the machine starts
immediately. Accordingly, when start-
3. Remove 2 solenoids (2) on the 2nd ECMV and ing the engine, check the moving direc-
the F or R ECMV and install plug M. tion of the machine and secure safety
q For forward travel: around the machine thoroughly and
F solenoid and 2nd solenoid keep pressing the brake pedal.
q For reverse travel: k After moving the machine, stop the
R solenoid and 2nd solenoid engine, apply the parking brake, and
a If a wrong solenoid is removed, the trans- put chocks under the tires.
mission may be broken. Take care.
a Install each plug with its projection side 6. After moving the machine, remove the devices
toward the ECMV. And make sure that the and return the removed parts.
O-ring is fitted to the mating face.
a Take care that mud or dirt will not enter the
removed solenoids and valves.
52 WA500-6
30 Testing and adjusting SEN00725-08
WA500-6 53
SEN00725-08
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 07-19 (01)
54
SEN00726-07
WA500-6
WA500-6 1
SEN00726-07 30 Testing and adjusting
2 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 3
SEN00726-07 30 Testing and adjusting
Adjusting
a When clearance (a) between front frame (4)
and rear frame (5) is out of the specified range,
adjust it in the following procedure.
1. Loosen locknut (2) and then tighten stopper
bolt (1) to set distance (b) to the minimum.
4 WA500-6
30 Testing and adjusting SEN00726-07
Testing and adjusting steering 3. Turn the steering wheel to the left and make
wheel 1 mark (C) at a position where the operating
effort becomes heavy. Then, measure the
a Testing and adjusting device for steering wheel
straight distance between marks (B) and (C).
Sym-
Part No. Part name
bol
N 79A-264-0021 Push-pull scale
Measuring method
1. Move the steering wheel to the right and left 2
– 3 times and check that the steering mecha-
nism is in neutral, and then make mark (A) on
the machine monitor frame.
WA500-6 5
SEN00726-07 30 Testing and adjusting
Measuring operating effort of steering wheel Measuring operating time of steering wheel
a Measure the operating effort of the steering a Measure the operating time of the steering
wheel under the following condition. wheel under the following condition.
q Road surface: Flat, level, paved and dried q Road surface: Flat, level, paved and dried
q Engine coolant temperature: q Engine coolant temperature:
Within operating range Within operating range
q Hydraulic oil temperature: q Hydraulic oil temperature:
Within operating range Within operating range
q Tire inflation pressure: q Tire inflation pressure:
Specified pressure Specified pressure
q Engine speed: Low idle (Bucket empty) q Engine speed: Low idle and high idle
2. Start the engine. 2. Turn the steering wheel to the right or left
a After starting the engine, raise the bucket stroke end.
about 400 mm and release the frame lock
lever. 3. Turn the steering wheel to the right or left
stroke end and measure the full-stroke time.
3. Pull push-pull scale N in the tangential direc- a Do not turn the steering wheel forcibly but
tion and read the value while the steering turn it at the speed of 60 revolutions per
wheel is moving smoothly. minute.
a The operating effort is not the value indi- a Measurement should be taken at low idle
cated when the steering wheel starts mov- and high idle turning the machine both in
ing. the right and left direction.
a The shape in the figure is not identical with a The shape in the figure is not identical with
that on WA500-6. that on WA500-6.
6 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 7
SEN00726-07 30 Testing and adjusting
3) Run the engine at high idle and turn the 2. Steering pilot circuit pressure
steering wheel to the right. When the 1) Remove side covers (3) and (4) of the
steering relief valve operates, measure steering valve situated in the left side of
the oil pressure. the machine.
a When the gauge was connected to
the steering circuit pressure pickup
plug on the left side steering cylinder
head, measure the pressure by turn-
ing the steering wheel counterclock-
wise.
8 WA500-6
30 Testing and adjusting SEN00726-07
5) While running the engine at high idle, 2) Remove steering LS circuit pressure hose
measure the oil pressure as the steering (11) of steering valve assembly (5).
wheel is turned.
q When measuring at hose (6): Turn
the steering wheel clockwise (or turn
the joystick steering lever rightward)
q When measuring at hose (7): Turn
the steering wheel counterclockwise
(or turn the joystick steering lever left-
ward)
WA500-6 9
SEN00726-07 30 Testing and adjusting
10 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 11
SEN00726-07 30 Testing and adjusting
2. Measuring fan drive oil pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan drive oil pressure.
2) Remove fan net (2) at the center.
12 WA500-6
30 Testing and adjusting SEN00726-07
3. Measuring fan reverse solenoid output 5) Turn the cooling fan reverse switch ON.
pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan reverse solenoid drive oil
2) Remove fan net (2) at the center. pressure.
a Measure the fan forward and reverse
drive oil pressures. When the fan is
reversed, check that the solenoid
operates and the specified oil pres-
sure is applied.
WA500-6 13
SEN00726-07 30 Testing and adjusting
Bleeding air from hydraulic drive 3) As oil free from air started to flow out of air
fan circuit 1 bleeder (3), tighten air bleeder (3).
3 Air bleeder:
a Testing tools for bleeding air from hydraulic
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
drive fan circuit
4) Start the engine and run it at low idle for 5
minutes minimum.
Symbol Part Number Part name
799-101-5002 Hydraulic tester 2. Bleeding air from fan motor circuit
1 1) Open radiator grille (4).
790-261-1204 Digital hydraulic tester
2) Remove fan net (5) at the center.
799-101-5220 Nipple (10 x 1.25 mm)
S 2
07002-11023 O-ring
3 799-401-3500 Adapter (Size 06)
4 790-261-1130 Coupling
14 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 15
SEN00726-07 30 Testing and adjusting
16 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 17
SEN00726-07 30 Testing and adjusting
18 WA500-6
30 Testing and adjusting SEN00726-07
2) Turn the handle (a) of the gas charging Table 1: Accumulator charging gas pres-
tool A fully to the let (Between accumula- sure chartt
tor (1) and gas charging tool A: Close). Ambient Charging nitrogen gas
Turn the handle (b) fully to the right to temperature front rear front rear
°C Remarks
close. MPa kg/cm2
a The gas does not leak from the hose 15 10.52 6.09 107.14 61.92
connection to the atmosphere, since 16 10.55 6.12 107.51 62.14
the valve (5) on the hose connection 17 10.59 6.14 107.88 62.35
side of the gas charging tool A is a 18 10.63 6.16 108.26 62.57
19 10.66 6.18 108.63 62.78
check valve (one way).
Standard gas
a The valve is closed by turning the 20 10.70 6.20 109.00 63.00
pressure
handle (a) counterclockwise. The 21 10.74 6.22 109.37 63.22
valve is open by turning the handle 22 10.77 6.24 109.74 63.43
(a) clockwise (Between charge valve 23 10.81 6.26 110.12 63.65
and accumulator: Open). 24 10.85 6.28 110.49 63.86
a The handle (a) is a screw-in type to 25 10.88 6.31 110.86 64.08
open the valve. 26 10.92 6.33 111.23 64.29
a The valve is open (open to the atmo- 27 10.96 6.35 111.60 64.51
28 10.99 6.37 111.98 64.72
sphere) by turning the handle (b) to
29 11.03 6.39 112.35 64.94
the let (counterclockwise). The valve
30 11.07 6.41 112.72 65.15
is closed (close to the atmosphere) by 31 11.10 6.43 113.09 65.37
turning the handle (b) to the right 32 11.14 6.45 113.46 65.58
(clockwise). 33 11.17 6.48 113.84 65.80
a The handle (b) is a screw-in type to 34 11.21 6.50 114.21 66.01
close the valve. 35 11.25 6.52 114.58 66.23
36 11.28 6.54 114.95 66.44
37 11.32 6.56 115.32 66.66
38 11.36 6.58 115.70 66.87
39 11.39 6.60 116.07 67.09
40 11.43 6.62 116.44 67.30
41 11.47 6.64 116.81 67.52
42 11.50 6.67 117.18 67.73
43 11.54 6.69 117.56 67.95
44 11.58 6.71 117.93 68.16
45 11.61 6.73 118.30 68.38
WA500-6 19
SEN00726-07 30 Testing and adjusting
5. When reducing the nitrogen gas pressure in 9. Apply soapy water to gas valve (4) of the accu-
the accumulator after testing the nitrogen gas mulator, and check that the nitrogen gas is not
pressure in the accumulator leaked.
a Initial state: The handle (a) is open.
1) Turn the handle (b) to the left slowly to dis- 10. Install the cap (3) and plug (2) to accumulator
charge the nitrogen gas gradually from the (1).
thread part of the handle (b) until the 3 Plug (2):
gauge of the gas charging tool A indicates 73.5 to 98.0 Nm {7.5 to 10.0 kgm}
that the pressure is the specified pressure
shown in the Table 1, and close the valve
by turning the handle (b) clockwise to
adjust the nitrogen gas pressure in the
accumulator (1).
2) Perform the adjustment according to the
procedure in Step 7 or after.
20 WA500-6
30 Testing and adjusting SEN00726-07
3. Connect the gas charging tool A and nitrogen 6) Turn the handle (c) of the regulator D fully
gas cylinder C to gas valve (4) of accumulator counterclockwise until it stops. Connect
(1) according to the following procedure. the regulator D to the nitrogen gas cylin-
1) Turn the handle (a) of gas charging tool A der F.
counterclockwise until it stops. (Between
accumulator (1) and gas charging tool A:
Close)
a The valve is closed by turning the
handle (a) counterclockwise. The
valve is open by turning the handle
(a) clockwise (Between charge valve
and accumulator: Open).
a The handle (a) is a screw-in type to
open the valve.
2) Turn the handle (b) counterclockwise for
opening. (Between handle (b) and atmo-
sphere: Open for bleeding air from the
hose)
a The valve is open (open to the atmo- a Connect the regulator D by using
sphere) by turning the handle (b) to another nipple E depending on the
the let (counterclockwise). The valve specification of the nitrogen gas cylin-
is closed (close to the atmosphere) by der.
turning the handle (b) to the right a The regulator is closed (stops dis-
(clockwise). charging the gas) by turning the han-
a The handle (b) is a screw-in type to dle (c) counterclockwise. The regulator
close the valve. is open (discharging the gas) by turn-
ing the handle (c) clockwise.
a The handle (c) is a screw-in type to
open the regulator.
7) Connect the hose B to the bushing C and
the regulator D.
WA500-6 21
SEN00726-07 30 Testing and adjusting
22 WA500-6
30 Testing and adjusting SEN00726-07
6. When the gauge of the gas charging tool indi- 8. Apply soapy water to gas valve (4) of the accu-
cates that the pressure exceeds the specified mulator, and check that the nitrogen gas is not
gas pressure shown in Table 1. leaked.
1) Turn the handle (a) counterclockwise to
close the valve of the regulator D.
2) Turn the handle (b) counterclockwise
slowly to discharge the nitrogen gas grad-
ually from the thread part of the handle (b)
until the gauge of the gas charging tool A
indicates that the pressure is the specified
pressure shown in the Table 1, and close
the valve by turning the handle (b) clock-
wise to adjust the nitrogen gas in the
accumulator (1).
WA500-6 23
SEN00726-07 30 Testing and adjusting
3. Turn the starting switch to ON position. 4. When the nitrogen gas is no longer dis-
Depress the brake pedal several times, and charged, left the handle (a) as it is, and remove
co unt the nu mbe r of tim es the bra ke is the gas charging tool A from the accumulator
depressed when the brake oil pressure caution (1).
lamp lights up.
q When the brake is depressed less than 5 5. Remove the extension A1.
times: The accumulator nitrogen gas pres-
sure may be low 6. Dispose of the accumulator.
q When the brake is depressed more than 5 a Dispose of the accumulator (1) while the
times: The accumulator nitrogen gas pres- gas valve (4) is left opened at the step 4.
sure is normal
24 WA500-6
30 Testing and adjusting SEN00726-07
Measuring
1. Remove front cover (1) of the accumulator
installation position situated on the right side of
the machine.
Adjusting
a If the accumulator charge cut-out pressure is
adjusted, the cut-in pressure changes accord-
ing to the valve area ratio.
WA500-6 25
SEN00726-07 30 Testing and adjusting
26 WA500-6
30 Testing and adjusting SEN00726-07
Measuring
1. Wheel brake oil pressure
1) Remove cover (1).
WA500-6 27
SEN00726-07 30 Testing and adjusting
2. Drop in wheel brake oil pressure 5) Start the engine and accumulate pressure
1) Remove cover (1). in the accumulator.
6) Stop the engine and press the left brake to
set the oil pressure to 5.9 MPa {60 kg/
cm2}. Maintain this state for 5 minutes and
then measure the pressure drop.
a Use care so that the brake pedal may
not be moved for 5 minutes.
a Remove the measuring instruments
after the measurement and return the
currently removed parts to their origi-
nal position. Then bleed air from the
wheel brake circuit. For details, see
"Bleeding air from wheel brake cir-
cuit".
28 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 29
SEN00726-07 30 Testing and adjusting
Bleeding air from brake circuit 1 4) Press the brake pedal and loosen bleeder
screw (2) about 1/2 turn to drain the oil.
Tighten bleeder screw (2) a nd the n
k Stop the machine on a level ground and release the brake pedal slowly.
apply the parking brake.
k Lock the tires with chocks and support the a This work must be performed by 2 work-
lift arm with the fall prevention rod. ers. One worker presses the brake pedal
and the other drains the oil through the
a After removing and installing a brake circuit bleeder screw.
part, bleed air from the brake circuit according a If the accumulator pressure decreases,
to the following procedure. start the engine to increase the pressure.
a Bleed air from the front brake circuit and rear
brake circuit according to the same procedure. 5) Repeat the above operation. When no
bubbles are contained in the oil flowing
1. Bleeding air from slack adjuster out of hose, press the pedal fully and
tighten bleeder screw while the oil is flow-
k Never bleed air while the engine is running ing out.
3 Bleeder screw:
since the drive shaft is rotating.
7 – 9 Nm {0.7 – 0.9 kgm}
1) Start the engine and increase the accumu-
lator pressure. Check that the accumula- 6) Similarly to the above, bleed air from rear
tor pressure is increased and stop the slack adjuster (3).
engine.
2) Remove inspection cover (1) on the front
side of the machine.
30 WA500-6
30 Testing and adjusting SEN00726-07
2. Bleeding air from brake cylinder 4) Repeat the above operation. When no
bubbles are contained in the oil flowing
k Never bleed air while the engine is running out of hose [1], press the pedal fully and
since the drive shaft is rotating. tighten bleeder screw (2) while the oil is
flowing out.
1) Remove cover (1). 3 Bleeder screw:
7 – 9 Nm {0.7 – 0.9 kgm}
5) Similarly to the above, bleed air from each
brake cylinder.
a Bleed air from the brake cylinders in
order from the one farthest from the
brake valve.
Air bleeding order of cylinders
(1) Left rear brake cylinder
O
(2) Right rear brake cylinder
O
(3) Right front brake cylinder
O
2) Connect one end of hose [1] to bleeder (4) Left front brake cylinder
screw (2) and put the other end in an oil
receiver. a After bleeding air, carry out the brake perfor-
mance test to check for abnormality.
Then, drain oil again through each bleeder
screw to see if any bubbles are contained in it.
a After finishing bleeding air, run the engine at
low idle and check the oil level in the hydraulic
tank. If the level is low, add oil up to the speci-
fied level.
WA500-6 31
SEN00726-07 30 Testing and adjusting
32 WA500-6
30 Testing and adjusting SEN00726-07
Measuring method
1. Start the engine and set the machine in the
straight travel position, and then drive up a
slope of 1/5 gradient with no load in the bucket.
WA500-6 33
SEN00726-07 30 Testing and adjusting
34 WA500-6
30 Testing and adjusting SEN00726-07
2. Parking brake emergency release valve 5) While running the engine at low idle, mea-
pilot pressure (Transmission ECMV basic sure the parking brake pilot pressure.
pressure) k Keep pressing the brake pedal for
1) Open rear frame left side cover (1). safety.
a Measure the oil pressure at turning
OFF of the parking brake.
WA500-6 35
SEN00726-07 30 Testing and adjusting
3. Parking brake solenoid valve output pres- 5) Run the engine at low idle and measure
sure output pressure of the parking brake sole-
1) Remove rear frame left side cover (1). noid valve.
k Keep pressing the brake pedal for
safety.
a Measure the oil pressure at turning
OFF of the parking brake.
a If the parking brake pilot pressure is
normal and parking brake solenoid
valve output pressure is abnormal,
failure on the check valve on the
parking brake solenoid inlet side or
failure on the parking brake solenoid
can be suspected.
36 WA500-6
30 Testing and adjusting SEN00726-07
Testing wear of parking brake 4. If depth (a) is over the wear limit, remove park-
disc 1 ing brake disc (4) and measure its thickness
(W), referring to Disassembly and assembly,
Measuring instruments
"Removal of parking brake disc".
Symbol Part No. Part name q Service limit thickness (W): 2.97 mm
Commercially a If the parking brake disc thickness is
X Slide calipers below the service limit, replace the disc.
available
WA500-6 37
SEN00726-07 30 Testing and adjusting
Method of releasing parking brake 3. Prepare 2 cage mounting bolts (2) and tighten
manually 1 them alternately in plug (1) installation position.
a Remove 2 bolts (2) on the diagonal posi-
a The parking brake is controlled hydraulically. If
tions.
you cannot release the parking brake because
a Tighten 2 bolts (2) to pull piston (3) and
of a trouble in the transmission, emergency
release the parking brake.
release solenoid valve, etc., you can move the
a Tighten the 2 bolts gradually and evenly.
machine by releasing the parking brake manu-
(After they reached the seats, give about 4
ally.
turns further to them.)
k Releasing the parking brake manually is a
means to move the machine from a danger-
ous job site to a safe place. Apply this
means only in an emergency.
k Lower the work equipment to the ground
and put chocks under the tires to prevent
the machine from moving.
k When applying this means, stop the engine.
38 WA500-6
30 Testing and adjusting SEN00726-07
Measuring
1. Operating effort of work equipment control
lever
1) Install and fix tool Y1 to the work equip-
ment control lever.
a Install tool Y1 to the center of the
knob.
a Operate the work equipment control
lever at the ordinary operating speed
and measure the minimum necessary
effort to operate the knob.
a The shape in the figure is not identical
with that on WA500-6.
WA500-6 39
SEN00726-07 30 Testing and adjusting
Measuring
1. PPC oil pressure (shut-off valve basic pres-
sure)
1) Remove front cover (1) in the accumulator
installation position situated on the right
side of the machine.
40 WA500-6
30 Testing and adjusting SEN00726-07
5) Maintain the work equipment lock lever at 2) Connect adapter Z2 and hose (4).
LOCK position. 3) Connect nipple [2] and oil pressure gauge
6) Start and run the engine at high idle and [1] of hydraulic tester Z1.
then measure the PPC oil pressure (shut- a Use the oil pressure gauge with
off valve basic pressure). capacity 6.0 MPa {60 kg/cm2}.
7) Remove the measurement tool after the 4) Set the work equipment lock lever to Free
measurement, and make sure that the position.
machine is back to normal condition. 5) Start and run the engine at high idle and
then measure the PPC oil pressure (shut-
2. PPC oil pressure (shut-off valve output off valve output pressure).
pressure) k Do not operate the work equipment
WA500-6 41
SEN00726-07 30 Testing and adjusting
Measuring work equipment oil 2) Disconnect hose (4) from union (3) of
pressure 1 work equipment control valve (2).
a Measuring instruments for work equipment oil
pressure
Symbol Part Number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
799-101-5220 Nipple (10 x 1.25 mm)
ZA 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
4 799-401-3200 Adapter (size 03)
Measuring
1. Preparation work
1) Lower section (b) to the ground keeping 3) Connect adapter ZA4 between union (3)
(a) of bucket 30 – 50 mm off the ground. and hose (4).
2) After stopping the engine, lower bucket 4) Connect nipple [2] in hydraulic tester ZA1
bottom (a) and (b) to the ground operating and oil pressure gauge [1] of hydraulic
the work equipment control lever. Make tester ZA1.
sure they are on the ground. a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
42 WA500-6
30 Testing and adjusting SEN00726-07
6) Remove the measurement tool after the 3) Connect adapter ZA4 between union (3)
measurement, and make sure that the and hose (4).
machine is back to normal condition. 4) Connect nipple [2] in hydraulic tester ZA1
k After measuring the oil pressure, and oil pressure gauge [1] of hydraulic
release pressure in the circuit and tester ZA1.
then remove the oil pressure a Use the oil pressure gauge of 40 MPa
gauge, nipple and adapter using {400 kg/cm2}.
the same procedure as 1. Prepara-
tion work.
WA500-6 43
SEN00726-07 30 Testing and adjusting
44 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 45
SEN00726-07 30 Testing and adjusting
Adjusting
a Adjustment of the unload valve is not available.
46 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 47
SEN00726-07 30 Testing and adjusting
Bleeding air from work equipment 2. Bleeding air from hydraulic cylinder
circuit 1 1) Start the engine and run it at low idle for 5
minutes minimum.
1. Bleeding air from work equipment pump
2) While running the engine at low idle,
(piston pump)
repeat raising and lowering of the lift arm 4
1) Remove side cover (1) on the work equip-
– 5 times.
ment pump.
a Do not operate the piston rod beyond
a position 100 mm in front of the
stroke end to prevent relieving.
3) Implement operation of 2) above with the
engine at high idle. Then operate the pis-
ton rod to the stroke end at low idle to
relieve it.
4) Implement the same operation as 2) and
3) above for the bucket and steering, too.
a When a cylinder is replaced, this
operation should be implemented
before connecting the piston rod.
48 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 49
SEN00726-07 30 Testing and adjusting
Method of moving machine when 3. Start the engine and set emergency parking
removing operator cab (when brake release switch (3) to the release side to
enable the machine to move to a maintenance
separate cab and floor shop or safe place.
specification) 1 k Remove the chocks to move the
50 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 51
SEN00726-07 30 Testing and adjusting
52 WA500-6
30 Testing and adjusting SEN00726-07
Adjusting
a If clearance (a) does not conform to the stan-
dard value, adjust it according to the following
procedure.
WA500-6 53
SEN00726-07 30 Testing and adjusting
54 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 55
SEN00726-07 30 Testing and adjusting
1. Machine monitor
1) Disconnect the following connectors from
cover (1).
q L58 connector: Parking brake switch
2) Remove interior covers (2).
q L59 connector: ECSS switch
3) Remove cover (1).
q L65 connector: Machine monitor mode
selector switch 2
q L66 connector: Machine monitor mode
selector switch 1
q L67 connector: Front working
lamp switch
q L68 connector: Rear working
lamp switch
q L69 connector: Load meter mode
selector switch
(if equipped)
q L70 connector: Load meter mode
display switch
(if equipped)
q L72 connector: Beacon lamp switch
(if equipped)
4) Remove bracket mounting bolt (4) of
a Pull out switches from the cover and
machine monitor (3) to turn over the
then disconnect the connectors.
machine monitor.
a Do not try to forcibly disconnect the
a Use care in this operation so that the
connectors inserting your hand
wiring harness may not be forcibly
through the bottom of the cover. Such
pulled.
action can damage the connectors or
switches.
56 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 57
SEN00726-07 30 Testing and adjusting
58 WA500-6
30 Testing and adjusting SEN00726-07
WA500-6 59
SEN00726-07
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 07-19 (01)
60
SEN00727-05
WA500-6
WA500-6 1
SEN00727-05 30 Testing and adjusting
For detailed procedures to start KOMTRAX operation, please contact the division in charge of KOMTRAX.
2 WA500-6
30 Testing and adjusting SEN00727-05
Station opening check in machine side 3. When about 5 seconds elapsed after the start-
a Complete steps 3. to 5. within 60 seconds. If ing switch was set to ACC, make sure that the
60 seconds or above elapsed, begin with step 7-segment indicator lamp changes to hyphen
1. again. “–” on the KOMTRAX terminal.
1. Turn OFF the starting switch and then, after
making sure 5 seconds have elapsed, proceed
to the next step.
WA500-6 3
SEN00727-05 30 Testing and adjusting
6. Make sure that the 7-segment indicator lamp is a As [Normal] is indicated, proceed to the
indicated normally on the KOMTRAX terminal. next step.
a If so, the 7-segment indicator lamp will a If “–” remains displayed, execute steps 1.
indicate characters “d”, “0”, and “–” repeat- to 5. again.
edly for 30 seconds after step 5. was
ended.
a Those characters, even if displayed nor-
mally, will change to a character other
than hyphen “–”after 30 seconds or above
elapsed.
The display may change to a character
other than “0” even within 30 seconds.
4 WA500-6
30 Testing and adjusting SEN00727-05
a If [Network trouble] is indicated, check the 10. Turn the starting switch OFF.
display of [LED-C4] referring to “Lamp dis-
play of KOMTRAX terminal”. If the CAN is 11. Make sure that the 7-segment indicator lamp is
not recognized, check the CAN harness of displayed normally after 5 seconds elapsed.
the KOMTRAX terminal, and then if there a When [Normal] appears, station opening
is any abnormality, repair it and start from check is completed.
procedure 1. again. a If [Abnormal] appears, station opening
[A]: Normal check does not end normally, so you
[B]: GPS position data detection trouble should perform the procedure above from
[C]: Reception trouble step 1. again.
[D]: GPS position data detection trouble a If station opening check ends normally, it
and reception trouble should not be rechecked.
[E]: Network trouble
WA500-6 5
SEN00727-05 30 Testing and adjusting
6 WA500-6
30 Testing and adjusting SEN00727-05
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
WA500-6 7
SEN00727-05 30 Testing and adjusting
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
8 WA500-6
30 Testing and adjusting SEN00727-05
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
WA500-6 9
SEN00727-05 30 Testing and adjusting
Devices or optional parts being replaced, disassembled, assembled or added Adjustment item (order)
Machine monitor N, K, L, M, A, B, C
Transmission main body E, D, F
Transmission controller A, B, E. D, F
Transmission ECMV solenoid E, D, F
Lift arm angle sensor G, K, L, M
Work equipment control valve I
Work equipment EPC solenoid I
Work equipment electric lever H
Work equipment controller A, B, G, H, I
Work equipment bucket horizontal proximity switch J
Bucket J, K, L, M
Lift arm B, G, J, K, L, M
Adding and removing an optional device B
*1: Section No. of “Service mode” in “Special functions of machine monitor (EMMS)”
*2: See “Testing and adjusting bucket positioner” and “Checking proximity switch operation indication
lamp”.
*3: See Attachment options, “Using load meter” of the Operation and maintenance manual.
10 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 11
SEN00727-05 30 Testing and adjusting
*1: This display is not available when the load meter function is turned off through OPT selection of service
mode.
*2: This display is not available when the travel speed and engine speed displays are turned off on the
character display by selecting OPT in the service mode.
12 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 13
SEN00727-05 30 Testing and adjusting
14 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 15
SEN00727-05 30 Testing and adjusting
16 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 17
SEN00727-05 30 Testing and adjusting
9. Travel speed/engine speed display selecting 11. Action code display function
function If a trouble occurs, the machine monitor dis-
A unit to be used for the machine monitor plays an action code corresponding to the seri-
speed display is selectable from km/h and ousness of the trouble to alert the operator for
MPH. It is also possible to display the travel appropriate actions.
speed and engine speed. a The figure below shows an example of the
a This function is available only when “RPM screen on which action code [E03] and
OPT” in the options is selected. [CALL + Telephone number] are alter-
a For details, see the “Other functions of nately displayed.
machine monitor” of the “Operation” sec- a When action code [E01] or [E02] is dis-
tion in the Operation and maintenance played, [CALL + Telephone number] is not
manual. displayed.
18 WA500-6
30 Testing and adjusting SEN00727-05
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code (location code + problem
failure code corresponding to the failure cur- code)
rently warned. B: Controller code
a The failure codes which have been MON : Machine monitor
detected in the past are separated into TM : Transmission controller
electrical and mechanical systems and WRK : Work equipment controller
recorded as failure history (refer to Ser- ENG : Engine controller
vice mode for a detail). C: The system where failure occurred
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display Screen
will be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 60 seconds,
the action code display screen is automat-
ically displayed.
WA500-6 19
SEN00727-05 30 Testing and adjusting
Service mode (*1): When the cursor is located at the leftmost posi-
1. Procedure for switching to Service mode tion, pressing the switch restores the normal
and screen display screen (Operator mode).
When using Service mode, carry out the fol- When the cursor is at a location other than the
lowing special operation to switch the screen leftmost position, pressing the switch returns
display. the cursor to the leftmost position.
1-1. Checking screen display If any switch operation is not done for 60 sec-
Make sure that the machine monitor is set to onds or more from ID input screen, the normal
the operator mode and any of “Service meter”, screen is automatically turned on.
“Action code” or “Failure code” is displayed on
the screen.
1-2. Displaying ID input initial screen
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
20 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 21
SEN00727-05 30 Testing and adjusting
22 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 23
SEN00727-05 30 Testing and adjusting
4-2. Displaying sub menu 4-4. Setting the 1 item individual monitoring
Press [U] switch while the menu is selected to 1) Select the target controller system of mon-
display the sub menu initial screen. itoring from the sub menu screen.
24 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 25
SEN00727-05 30 Testing and adjusting
26 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 27
SEN00727-05 30 Testing and adjusting
21 40400 Lift arm bottom pressure BOOM BTM PRESS 0.00 – 50.00
22 40402 Lift arm bottom pressure BOOM BTM PRESS 0.00 – 5.00
28 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 29
SEN00727-05 30 Testing and adjusting
23 40500 Lift arm head pressure BOOM HEAD PRESS 0.00 – 50.00
24 40501 Lift arm head pressure BOOM HEAD PRESS 0.00 – 5.00
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and
item name may be displayed on the machine monitor.
30 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 31
SEN00727-05 30 Testing and adjusting
32 WA500-6
30 Testing and adjusting SEN00727-05
4 40903 D-IN-28 — —
D-IN-29 Engine oil level Normal oil level = ON (GND)/OFF (OPEN)
Operation of emergency steering
motor (Applicable to a machine Emergency steering operation = ON (GND)/OFF
D-IN-30
equipped with the optional emer- (OPEN)
gency steering)
D-IN-31 — —
Load meter subtotal switch
D-IN-32 Pressing of switch = ON (GND)/OFF (OPEN)
(Load meter specifications)
Load meter cancel switch
D-IN-33 Pressing of switch = ON (GND)/OFF (OPEN)
(Load meter specifications)
D-IN-34 High beam (dimmer switch) High beam = ON (GND)/OFF (OPEN)
5 40904 D-IN-35 — —
D-IN-36 Service switch ON =ON(GND)/OFF(OPEN)
D-IN-37 > switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38 < switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-39 — —
D-OUT-0 Alarm buzzer Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 — —
6 40952
D-OUT-2 — —
D-OUT-3 — —
WA500-6 33
SEN00727-05 30 Testing and adjusting
5 41400 Fan pump EPC current value (Command) FAN EPC DIR 0 – 1000
14 41203 Transmission cut-off operation setting T/M CUT SET 0.00 – 5.00
15 41201 Transmission cut-off (left brake) pressure T/M CUT OFF P 0.00 – 5.00
16 41202 Transmission cut-off (left brake) pressure T/M CUT OFF P 0.00 – 5.00
20 92400 Modulation clutch oil pressure input MOD/C PRESS 0.00 – 50.00
21 92401 Modulation clutch oil pressure input voltage MOD/C PRESS 0.00 – 5.00
22 92500 Modulation clutch calorific value MOD/C Q 0 – 25.5
23 92501 Modulation clutch calorific rate MOD/C q 0 – 2.55
Throttle lock switch (press-up)
24 95500 THROT LOCK A Arabic numerals
(RPM set switch)
Throttle lock switch (pressed downward)
25 95501 THROT LOCK B Arabic numerals
(RPM set auto deceleration switch)
34 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 35
SEN00727-05 30 Testing and adjusting
56 94100 Clutch trigger initial learning flag TRIG FR1234 0/1 (ON/OFF)
36 WA500-6
30 Testing and adjusting SEN00727-05
0 – 1000 [mA] mA
0 – 1000 [mA] mA
Status display
Status display
Status display
Status display
Status display
Status display
Status display Not used in this machine.
Status display Not used in this machine.
0: ON
Status display
1: OFF
WA500-6 37
SEN00727-05 30 Testing and adjusting
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and
item name may be displayed on the machine monitor.
38 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 39
SEN00727-05 30 Testing and adjusting
40 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 41
SEN00727-05 30 Testing and adjusting
6 94500 Loader pump EPC current (Command) PUMP EPC DIR 0 – 1000
12 42000 Lever potentiometer voltage lift arm 1 BOOM POT1 0.00 – 5.00
13 42001 Lever potentiometer voltage lift arm 2 BOOM POT2 0.00 – 5.00
0 – 256000
14 42101 Bucket lever operation frequency BUCKET LVR
(In a thousand of times)
17 41900 Lift arm raise EPC current (Command) RAISE EPC DIR 0 – 1000
18 41901 Lift arm lower EPC current (Command) LOWER EPC DIR 0 – 1000
42 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 43
SEN00727-05 30 Testing and adjusting
19 41902 Bucket tilt EPC current (Command) TILT EPC DIR 0 – 1000
20 41903 Bucket dump EPC current (Command) DUMP EPC DIR 0 – 1000
22 41904 AJSS right EPC current (Command) J/S EPC DIR RH 0 – 1000
23 41905 AJSS left EPC current (Command) J/S EPC DIR LH 0 – 1000
29 42006 Lever potentiometer voltage 3-spool valve 1 3RD POT1 0.00 – 5.00
30 42007 Lever potentiometer voltage 3-spool valve 2 3RD POT2 0.00 – 5.00
44 WA500-6
30 Testing and adjusting SEN00727-05
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and
item name may be displayed on the machine monitor.
WA500-6 45
SEN00727-05 30 Testing and adjusting
4 40913 Remote positioner raise/lower set switch Remote positioner raise/lower set switch
D-IN-28
(RAISE) (RAISE) = ON (GND)/OFF (OPEN)
Remote positioner raise/lower set switch Remote positioner raise/lower set switch
D-IN-29
(LOWER) (LOWER) = ON (GND)/OFF (OPEN)
D-IN-30 — —
D-IN-31 — —
46 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 47
SEN00727-05 30 Testing and adjusting
48 WA500-6
30 Testing and adjusting SEN00727-05
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as “Not used” though its code and item name may be
displayed on the machine monitor.
WA500-6 49
SEN00727-05 30 Testing and adjusting
50 WA500-6
30 Testing and adjusting SEN00727-05
WA500-6 51
SEN00727-05
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
52
SEN00728-07
WA500-6
WA500-6 1
SEN00728-07 30 Testing and adjusting
a Adjustment function
2 WA500-6
30 Testing and adjusting SEN00728-07
3) Press [U] switch to settle the real-time 7-1-2. Conformation of transmission oil temperature
monitoring of the transmission controller. control
a As the selection is settled, the application 1) Start the engine, press the brake pedal
program version of the transmission con- fully and then release the parking brake.
troller will be displayed. 2) Set the transmission shift mode to “Man-
q [20223] : ID number of display item ual”; set the FNR (directional) lever, joy-
q [ ]: Display of data (Program stick steering FNR (directional) switch or
version) right FNR (directional) switch to “F (for-
ward)”; and shift lever or switch to “4th”.
3) Make sure from “7-1-1 Preparations for
transmission ECMV current adjustment”
that the transmission controlled oil tem-
perature is 70 – 80°C. If it is out of the
range, stall the torque converter and
adjust the temperature to 70 – 80°C.
4) Return the FNR (directional) lever, joystick
steering FNR (directional) switch, or right
FNR (directional) to “N (neutral)” and
maintain it in that position. After 3 minutes,
make sure the oil temperature is still in the
70 – 80°C range.
5) Let the oil pervade in the transmission by
operating the FNR (directional) lever or
4) Using [<] or [>] switch, move the cursor to
joystick steering FNR (directional) switch,
the T/M OIL TEMP screen.
right FNR (directional) switch, or gear shift
q [93600] : ID number of transmission
lever or switch in the following table.
control oil temperature
q [ ]: Display of transmission Operating
control oil temperature 1 2 3 4
order
Gear speed N2 F2 F1 F2
Min. Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec. 2 sec.
Operating
5 6 7 8
order
Gear speed F3 F4 F3 F2
Min. Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec. 2 sec.
Operating
9 10 11
order
Gear speed N2 R2 N2
Min. Min. Min.
Holding time
2 sec. 2 sec. 2 sec.
WA500-6 3
SEN00728-07 30 Testing and adjusting
7-1-3. Adjustment of transmission ECMV current 5) Using [<] or [>] switch from the sub menu,
a Targets of correction are 6 types – F (forward), select 02: ECMV TUNING.
R (reverse), 1st, 2nd, 3rd and 4th. As the
engine is started, correction of all of above
clutches is started automatically.
a Since the learning operation requires the spec-
ified oil temperature, the oil temperature must
be adjusted to 70 – 80°C range.
1) Turn on the starting switch (engine is not
started) and then display T/M OIL TEMP
referencing “7-1-1 Preparations for trans-
mission ECMV current adjustment”.
2) Make sure that the transmission controlled
oil temperature is in the 70 – 80°C range
when the engine is set to low idle; acceler-
ator pedal to OFF; FNR (directional) lever,
joystick steering FNR (directional) switch,
6) Press U switch to settle the adjustment
or right FNR (directional) switch to “N
item.
(neutral)”; and parking brake to ON.
7) Using [U] switch, select AUTO from the
3) Display the TUNING from the menu
automatic correction (AUTO) and manual
screen of Service mode.
correction (MANUAL) selection screen to
settle the automatic correction.
4 WA500-6
30 Testing and adjusting SEN00728-07
Operating
1 2 3 4
order
IP “IP F-1” “IP F-2” “IP F-3” “IP F-4”
ECMV/ F/2nd F/3rd F/4th
F/1st time
frequency time time time
Operating
5 6 7 8
order
IP “IP R-1” “IP R-2” “IP R-3” “IP R-4”
ECMV/ R/1st R/2nd R/3rd R/4th
frequency time time time time
Operating
9 10 11 12
order
IP “IP 1-1” “IP 1-2” “IP 1-3” “IP 1-4” a Codes for abnormal end
ECMV/ 1st/1st 1st/2nd 1st/3rd 1st/4th Reason CODE
frequency time time time time
Deviation from correction condition 1
Operating Absence of fill 2
13 14 15 16
order In excess of correction value 3
IP “IP 2-1” “IP 2-2” “IP 2-3” “IP 2-4”
ECMV/ 2nd/1st 2nd/2nd 2nd/3rd 2nd/4th a If abnormal end code “1” (NG1: Deviation
frequency time time time time from correction condition) was displayed,
set the condition again referencing “7-1-1
Operating Preparations for transmission ECMV cur-
17 18 19 20
order rent adjustment” and repeat the correc-
IP “IP 3-1” “IP 3-2” “IP 3-3” “IP 3-4” tion.
ECMV/ 3rd/1st 3rd/2nd 3rd/3rd 3rd/4th a If abnormal end code “2” (NG2: Absence
frequency time time time time of fill) was displayed, implement trouble-
shooting of the failure codes 15STLH and
Operating DXHTKA. If the state is normal, repeat the
21 22 23 24
order operation starting from “7-1-1 Prepara-
IP “IP 4-1” “IP 4-2” “IP 4-3” “IP 4-4” tions for transmission ECMV current
ECMV/ 4th/1st 4th/2nd 4th/3rd 4th/4th adjustment” and repeat the correction.
frequency time time time time (The value of T depends on the applica-
ble gear speed.)
8) As the correction is normally completed, a If the abnormal end code “3” (NG3: In
OK is displayed in the character display. excess of correction value) was displayed,
execute the troubleshooting of failure
code 15STL1. Then after making sure the
condition is normal, implement “7-1-1
Preparations for transmission ECMV cur-
rent adjustment” again. (The value of T
depends on the applicable gear speed.)
9) As the operation ended normally, turn the
starting switch off and the corrected value
will be stored on the transmission control-
ler after 3 seconds.
a When it is required to turn on the starting
switch immediately after the adjustment,
maintain the starting switch, just in case,
at off position for 10 seconds minimum
and then turn it on.
a If the correction is not normally ended, the
code for abnormal end will be indicated. (Fol-
lowing shows an example of the operation in
which the 1st time correction of the 3rd position
has ended abnormally).
WA500-6 5
SEN00728-07 30 Testing and adjusting
7-2. Setting of transmission initial learning 5) Press [U] switch to settle the adjustment
When initializing all the past initial trigger learn- item. As the item is settled, the initial
ing data stored on the transmission controller, learning reset screen appears.
employ the following procedure. a If the initial learning is not done, INITIAL
7-2-1. Reset of initial learning STATUS will be displayed.
1) Turn on the starting switch. (Engine does
not start)
2) Set the FNR (directional) lever, joystick
steering FNR (directional) switch, or right
FNR (directional) switch to “N (neutral)”.
3) Display the TUNING screen from the
menu screen of Service mode.
6 WA500-6
30 Testing and adjusting SEN00728-07
7-2-2. Preparations for transmission initial learning 4) Using [U] switch, settle 2 items display of
1) Display the REAL-TIME MONITOR from the transmission control oil temperature
the menu screen of Service mode. and the trigger learning display.
a Content of the trigger learning is displayed
for each of F, R, 1st, 2nd, 3rd and 4th
clutch in the figure.
q 0: Learning not done yet
q 1: Learning completed
WA500-6 7
SEN00728-07 30 Testing and adjusting
4) Perform the initial learning by operating q The shift point that is used when the hunt-
the FNR (directional) lever, joystick steer- ing prevention function is turned on.
ing FNR (directional) switch, right FNR q The shift down point that is used when the
(directional) switch, or gear shift lever or accelerator is set to idle.
switch in the following manner. a After a shift point adjustment is done, confirma-
tion on the machine must be done.
Operating
1 2 3 4 7-3-1. Clearing an adjusted shift point
order
1) Display the TUNING screen from the
Gear
N2 F2 F1 F2 menu screen of Service mode.
speed
Holding Min. 6 Min. 6 Min. 6 Min. 4
time sec. sec. sec. sec.
Operating
5 6 7 8
order
Gear
F3 F4 F3 F2
speed
Holding Min. 4 Min. 4 Min. 4 Min. 4
time sec. sec. sec. sec.
Operating
9 10 11
order
Gear
N2 R2 N2
speed
Holding Min. 4 Min. 4 Min. 4 2) Hold down [U] switch for 5 seconds mini-
time sec. sec. sec. mum to display 01: TM TRIGGER screen.
8 WA500-6
30 Testing and adjusting SEN00728-07
4) Press [U] switch to settle the selection. <Gear shift pattern change procedure>
a As the selection is settled, 0: ALL a As an example of a gear shift pattern change,
CLEAR will be displayed in the lower following describes the procedure for changing
space. the gear shift travel speed pattern from F2T/C
5) Press [U] switch to settle ALL CLEAR. to F3T/C. (The same applies to other gear shift
a As all the stored values are cleared, patterns, too.)
the screen returns to the shift point 1) Select 04: SHIFT rpm screen using [U]
adjustment item. switch and then select 01: F2T/C → F3T/C
a If [t] switch is pressed in place of [U] using [<] or [>] switch.
switch, the stored value is not cleared
and the screen returns to the adjust-
ment items.
WA500-6 9
SEN00728-07 30 Testing and adjusting
4) After selecting a desired setting data, 3) Using [<] or [>] switch, move the cursor to
press [t] switch to end the setup proce- item of 05: RAISE ANGLE.
dure.
10 WA500-6
30 Testing and adjusting SEN00728-07
a Lift arm length by lift arm specification 3) Using [<] or [>] switch, move the cursor to
item of 06: RAISE EPC.
Lift arm Voltage
Lift arm position
specification range
A Upper limit position 3.80 ± 0.3 V
(Stroke end of raised
B cylinder) 3.87 ± 0.3 V
Machine model A B
WA600-6 3850 mm 3990 mm
WA500-6 3250 mm 3636 mm
2) Hold down [U] switch for 5 seconds mini- a The setting is complete as 06: RAISE
mum to display 01: TM TRIGGER screen. EPC screen was restored succeeding to
two times of buzzer beep.
a If the lever output voltage at this point is
below the standard value (off the design
range), pressing [U] switch sounds the
buzzer for 1 second and the screen
remains unchanged as U = SET like
shown in the above figure. In this case,
the adjustment is cancelled and 06:
RAISE EPC screen will be restored.
a If [t] switch is pressed at this point, cor-
rection of variations in the work equipment
EPC lever detent position is stopped even
if it is not completed.
WA500-6 11
SEN00728-07 30 Testing and adjusting
7-5-2. Adjusting lift arm raise EPC starting current 4) Lower the lift arm by dumping the bucket
a Start the engine prior to the setup opera- and then lift the front wheel.
tion. 5) Start raising the lift arm gradually while
1) Display the TUNING screen from the setting the engine to high idle (the
menu screen of Service mode. machine body is lowered).
6) Return the lever through fine operation. As
the lift arm is stopped, maintain the lever
at that position (front wheel is floated).
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.
12 WA500-6
30 Testing and adjusting SEN00728-07
7-6. Adjustment of lift arm lower (float) lever 3) Using [<] or [>] switch, move the cursor to
and variations in the dead zone of EPC item of 07: LOWER EPC.
7-6-1. Adjusting variation correcting calibration of
lift arm lower (float) EPC lever
a This adjustment is needed when the electric
(EPC) work equipment lever is used or when
the work equipment controller was replaced.
a Before starting the adjustment, lower the lift
arm to the ground and stop the engine.
1) Display the TUNING screen from the
menu screen of Service mode.
WA500-6 13
SEN00728-07 30 Testing and adjusting
7-6-2. Adjusting lift arm lower EPC starting current 4) Set the lift arm roughly horizontal without
a Start the engine prior to the setup opera- applying any load.
tion. 5) Start lowering the lift arm gradually while
1) Display the TUNING screen from the maintaining the engine at high idle.
menu screen of Service mode. 6) Return the lever through fine operation. As
the lift arm is stopped, maintain the lever
at that position.
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.
14 WA500-6
30 Testing and adjusting SEN00728-07
7-7. Adjustment of bucket tilt lever and varia- 4) Stop the bucket tilt lever in a position just
tions in the dead zone of EPC before the tilt detent position and maintain
7-7-1. Adjusting variation correcting calibration of the lever at this position.
bucket tilt EPC lever a Take care so that the tilt detent operation
a This adjustment is needed when the electric may not be turned on.
(EPC) work equipment lever is used or when 5) Pressing [U] switch turns on reading of
the work equipment controller was replaced. lever voltage and then stores the read
a Before starting the adjustment, lower the lift voltage replacing the currently stored
arm to the ground and stop the engine. standard value.
1) Display the TUNING screen from the
menu screen of Service mode.
WA500-6 15
SEN00728-07 30 Testing and adjusting
7-7-2. Adjusting bucket tilt EPC starting current 4) Lower the lift arm by dumping the bucket
a Start the engine prior to the setup opera- and then lift the front wheel.
tion. 5) Start lowering the bucket gradually while
1) Display the TUNING screen from the maintaining the engine at high idle (the
menu screen of Service mode. machine body is lowered).
6) Return the lever through fine operation. As
the bucket is stopped, maintain the lever
at that position.
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.
16 WA500-6
30 Testing and adjusting SEN00728-07
7-8. Adjustment of bucket dump EPC starting 4) Set the bucket roughly horizontal without
current applying any load.
a Start the engine prior to the setup opera- 5) Start dumping the bucket gradually while
tion. maintaining the engine at high idle.
1) Display the TUNING screen from the 6) Return the lever through fine operation. As
menu screen of Service mode. the bucket is stopped, maintain the lever
at that position.
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.
WA500-6 17
SEN00728-07 30 Testing and adjusting
a Normally, change to tables No. 2 to No. 4 is made. When selecting No. 1 or No. 5 table, therefore, thor-
ough preliminary performance check and operator evaluation are required.
a The maximum lowering speed is not available from the data of Tables No. 1 and No. 2. Thus, when
measuring the lift arm lowering speed, Tables No. 3 – No.5 must be used.
18 WA500-6
30 Testing and adjusting SEN00728-07
1) Display the TUNING screen from the 4) Press [U] switch to settle the selection.
menu screen of Service mode. a As the selection is settled, the lift arm
lever table adjustment screen will be dis-
played.
WA500-6 19
SEN00728-07 30 Testing and adjusting
1) Display the TUNING screen from the 2) Hold down [U] switch for 5 seconds mini-
menu screen of Service mode. mum to display 01: TM TRIGGER screen.
20 WA500-6
30 Testing and adjusting SEN00728-07
WA500-6 21
SEN00728-07 30 Testing and adjusting
2) Hold down [U] switch for 5 seconds mini- 7-16. Adjustment of pump cut-off pressure in lift
mum to display 01: TM TRIGGER screen. arm raise
a This function modifies matching of the travel
speed and work equipment speed at dump
approach and hopper charge by changing the
condition of the lift arm bottom pressure, which
is used as a pump flow rate restricting condi-
tion when lifting given load.
a The following lists the pump flow rate restrict-
ing conditions applicable to load lifting opera-
tion.
If the lift arm is operated under the following
initial conditions, its speed is restricted to
approximately 70% and the remaining torque
is used for the travel.
q Lift arm angle > 0° (Horizontal)
q Bucket tilt end detecting proximity switch
3) Using [<] or [>] switch, move the cursor to
signal = Present (Tilt end detection avail-
item of 16: LOWER STOP.
able)
q Lift arm bottom pressure > 20 MPa
a Modifying the lift arm bottom pressure changes
the matching as shown in the table.
q The following data shows, when the
machine is loaded, the time required for
the lift arm to reach the lift arm top when
the raise operation was started simulta-
neously with start of the machine and the
travel distance at that time.
q Decreasing the currently set pressure acti-
vates the cut-off earlier, thereby lengthen-
ing the lift arm rising time as well as
extending the travel distance.
Lift arm F1 F2
4) Press [U] switch to settle the selection. bottom
a As the selection is settled, the LOWER Working pressure
STOP screen will appear. mode during ris- Distance Time Distance Time
5) Select a desired table from 0, 100 and 200 ing (MPa
by use of [<] or [>] switch. {kg/cm})
6) Press [t] switch to settle the adjustment. 10 {102] 16.5 11 25.1 11.2
Economy 20 {204] 15.5 10.7 24.7 10.7
25 {255] 15 10.2 24.5 10.6
10 {102] 17.8 10.7 26.7 11.1
Power 20 {204] 16.3 10.3 24.4 10.5
25 {255] 15.3 9.8 24.2 10.2
22 WA500-6
30 Testing and adjusting SEN00728-07
1) Display the TUNING screen from the 4) Press [U] switch to settle the selection.
menu screen of Service mode. a As the selection is settled, the pump cutoff
pressure adjustment screen will be dis-
played.
5) Select a desired pressure in the range of 5
– 45 (Unit: MPa) by use of [<] or [>] switch.
6) Press [t] switch to settle the adjustment.
WA500-6 23
SEN00728-07 30 Testing and adjusting
3) Using [<] or [>] switch, move the cursor to 8) When the adjustment did not end suc-
item of 18: RAISE ANGLE. cessfully, check the lift arm angle sensor
voltage from the real time monitoring.
a Adjust the lift arm angle sensor mounting
position so that the voltage displayed on
the real time monitoring may fall within the
following range and then implement the
sensor adjustment again.
24 WA500-6
30 Testing and adjusting SEN00728-07
3) Using [<] or [>] switch, move the cursor to 8) When the adjustment did not end suc-
item of 19: LOWER ANGLE. cessfully, check the lift arm angle sensor
voltage from the real time monitoring.
a Adjust the lift arm angle sensor mounting
position so that the voltage displayed on
the real time monitoring may fall within the
following range and then implement the
sensor adjustment again.
Lift arm position Voltage range
Lower limit position
0.5 – 4.5 V
(Stroke end of lowered cylinder)
WA500-6 25
SEN00728-07 30 Testing and adjusting
2) Hold down [U] switch for 5 seconds mini- 8. Maintenance monitoring function (MAINTE-
mum to display 01: TM TRIGGER screen. NANCE MONITOR)
The maintenance function offers the following
capabilities in the maintenance of filters and oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
26 WA500-6
30 Testing and adjusting SEN00728-07
4) Settle the target items of interval change a The shortest interval time value is 50 h.
by use of [U] switch. a When you have entered a wrong value to
a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
WA500-6 27
SEN00728-07 30 Testing and adjusting
6) Select “YES” or “NO” using [<] or [>] a When “Timer by item” is disabled, the
switch. order of display becomes OFF → ON.
a The selected cursor will start flashing. a The default display is ON.
If “YES” is selected and [t] switch is
pressed, the information will be deleted.
If “NO” is selected and [t] switch is
pressed, deletion is cancelled and the
maintenance interval change item screen
is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If “Timer by item” is disabled, OFF will be
displayed in the upper column.
28 WA500-6
30 Testing and adjusting SEN00728-07
3) Select “YES” or “NO” using [<] or [>] a The selected cursor will start flashing.
switch. If “YES” is selected and [t] switch is
a The selected cursor will start flashing. pressed, the change will be enabled.
If “YES” is selected and [t] switch is If “NO” is selected and [t] switch is
pressed, the information will be deleted. pressed, the change will not be imple-
If “NO” is selected and [t] switch is mented and the maintenance monitoring
pressed, deletion is cancelled and the screen will be restored.
maintenance interval change item screen
is restored.
a If the timer which has been stopped is set
effective, the interval time set before the
timer was stopped is applied.
The timer remaining time is reset. The
number of resets before the timer was
stopped is applied.
WA500-6 29
SEN00728-07 30 Testing and adjusting
30 WA500-6
30 Testing and adjusting SEN00728-07
7) As the timer stop for all items is executed: 2) Press [U] switch to display the fuel con-
a The timer function for all items is stopped sumption ratio and average fuel consump-
a n d t h e M A I N T E N A N C E M O N I TO R tion screen.
screen is restored. 3) Using [<] or [>] switch, select the item to
a Setting for individual items is also dis- be displayed from 1] – 4] on the fuel con-
abled. sumption ratio and average fuel consump-
a If cancelled: The operation is cancelled tion screen.
a n d t h e M A I N T E N A N C E M O N I TO R 1] Fuel consumption ratio and average
screen is restored. fuel consumption screen
8) When timer enable for all items is exe- a The upper column displays fuel con-
cuted: sumption [L/km or L/mile] per 1 km (or
a Interval time being set for all items is exe- 1 mile) from the last resetting.
cuted to the set value before disabled q Above value is computed from the
independent of whether or not it is fuel consumption ratio and travel dis-
enabled or disabled for a specific item. tance (odometer distance).
a The timer remaining time is reset. (The q The counting is stopped at 99999.9,
reset frequency remains the same as the upper limit.
before the resetting.) a The lower column displays the aver-
a The MAINTENANCE MONITOR screen is age fuel consumption [L/h] from the
restored. last resetting.
a Setting for individual items is also q The counting is stopped at 99999.9,
enabled. the upper limit.
a If cancelled: The operation is cancelled a Calculation is done only for the dura-
a n d t h e M A I N T E N A N C E M O N I TO R tion in which the engine is run.
screen is restored.
WA500-6 31
SEN00728-07 30 Testing and adjusting
32 WA500-6
30 Testing and adjusting SEN00728-07
WA500-6 33
SEN00728-07 30 Testing and adjusting
34 WA500-6
30 Testing and adjusting SEN00728-07
WA500-6 35
SEN00728-07 30 Testing and adjusting
36 WA500-6
30 Testing and adjusting SEN00728-07
10-1. Changing or settling lift arm model option 10-3. Setting tire deflection option
selection a Select the tire deflection option from the list of
a Pressing [U] switch from the 1: LIFT installed optional devices and their setting.
BOOM screen interchanges A and B. a Pressing [U] switch sequentially displays
a As A and B are interchanged, the sound [@@]% in the following order.
(beep) indicating acceptance of the opera- a The display progresses from +00 through –12.
tion will be generated. Pressing [U] switch at this point returns the
a Select the lift arm length for A and B from display to +00.
the following.
Machine model A B Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
WA600-6 3850 mm 3990 mm @@ +00 +02 +04 +06 +08 +10 +12
WA500-6 3250 mm 3636 mm Order No.8 No.9 No.10 No.11 No.12 No.13 No.14
@@ –02 –04 –06 –08 –10 –12 +00
WA500-6 37
SEN00728-07 30 Testing and adjusting
11. Machine serial number input function 12. Model selection function (MACHINE WA500)
(MACHINE No. SET) a The model selection function enables a
1) Display the MACHINE No. SET screen change of machine monitor model setting.
from the menu screen of Service mode. a Select a model first after initializing the
machine monitor.
a Selecting a model resets the optional set-
ting. If a model is selected, perform all the
optional settings in sequence from the
beginning.
38 WA500-6
30 Testing and adjusting SEN00728-07
3) Using [<] or [>], replace “WA600” with 13. Initialize function (INITIALIZE)
“WA500”. This function is used only in the factory. It is,
a Press [t] switch when stopping the model therefore, not used for a service purpose.
selection.
a As the operation is stopped, the sound
(beep) indicating cancellation of the oper-
ation acceptance will be generated,
restoring the MACHINE screen.
4) Settle the selected model by use of [U]
switch.
a As the selection is settled, the sound
(beep) indicating completion of the opera-
tion acceptance will be generated, restor-
ing the MACHINE screen.
a Make sure the model on the MACHINE
screen is the target model.
WA500-6 39
SEN00728-07 30 Testing and adjusting
Engine at high idle and torque converter kPa Max. 2.94 3.92
Blow-by pressure
stalled {mmH2O} {Max. 300} {400}
SAE0W30EOS Min. 0.34 0.21
Engine at high idle
SAE5W40EOS {Min. 3.5} {2.1}
Lubricating oil MPa
SAE10W30DH
pressure {kg/cm2} Min. 0.10 0.08
SAE15W40DH
Engine at low idle
SAE30DH {Min. 1.0} {0.8}
Engine at high idle and torque converter kPa Min. 116 89
Boost pressure
stalled {mmHg} {Min. 870} {670}
Exhaust Engine at high idle and toque converter stalled
°C Max. 650 700
temperature Outside temperature: 20°C
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
3.19 – 3.48 3.19 – 3.48
Engine at high idle
Main relief {32.5 – 35.5} {32.5 – 35.5}
pressure 3.49 – 3.79 3.49 – 3.79
Engine at low idle
• Torque converter oil {35.6 – 38.6} {35.6 – 38.6}
Torque converter pressure: 0.44 – 0.84 0.44 – 0.84
Engine at high idle
inlet pressure Within operating range {4.5 – 8.5} {4.5 – 8.5}
Torque converter • Transmission: Neutral 0.29 – 0.49 0.29 – 0.49
Engine at high idle
outlet pressure {3.0 – 5.0} {3.0 – 5.0}
Lubrication oil 0.10 – 0.25 0.10 – 0.25
Engine at high idle
Transmission valve
40 WA500-6
30 Testing and adjusting SEN00728-07
Standard
Service limit Measurement
Item Condition Unit value for new Good Bad
value result
machine
Steering
WA500-6 41
SEN00728-07 30 Testing and adjusting
Standard
Service limit Measurement
Item Condition Unit value for new Good Bad
value result
machine
• Engine speed: High idle
• Engine coolant temperature: Min. 95°C
Max. fan speed • Hydraulic oil temperature: Min. 95°C 1,055 ± 50 1,055 ± 100
• Torque converter oil temperature: Min.
105°C
• Engine speed: Low idle (*1) rpm
• Engine coolant temperature: Max. 75°C
Hydraulic drive fan
42 WA500-6
30 Testing and adjusting SEN00728-07
WA500-6 43
SEN00728-07
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
44
SEN00729-02
WA500-6
40 Troubleshooting 1
General information on troubleshooting
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
WA500-6 1
General information on troubleshooting
SEN00729-02 Points to remember when performing troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to
prevent reoccurrence of the failure.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how identifying rough causes of the given undesirable symptom through the interview
with the operator concerned can facilitate the troubleshooting.
1. When performing troubleshooting, do not hurry to disassemble the machine.
If the machine is disassembled immediately after any failure occurs,
q Parts that have no connection with the failure or other unnecessary parts are disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of staff-hours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting corresponding to the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything unusual about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Does the machine have abnormal symptoms?
2) Check "Check before starting" items.
3) Check other check items.
4) Check other maintenance matters which can be checked externally and are considered to be necessary.
4. Checking failure
Check the extent of the failure yourself, and judge whether it is a real failure or a problem of the method
of operation, etc.
a When operating the machine to reproduce the failure symptom, do not perform any investigation or
measurement that may make the problem worse.
2 WA500-6
General information on troubleshooting
Points to remember when performing troubleshooting SEN00729-02
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure,
then use the troubleshooting flowchart or troubleshooting flow (matrix) to locate the position of the failure
exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur
again. To prevent this, you must locate and eliminate the primary cause behind the given failure.
WA500-6 3
General information on troubleshooting
SEN00729-02 How to proceed in troubleshooting
4 WA500-6
General information on troubleshooting
How to proceed in troubleshooting SEN00729-02
WA500-6 5
General information on troubleshooting
SEN00729-02 Testing before troubleshooting
6 WA500-6
General information on troubleshooting
Classification and procedures of troubleshooting SEN00729-02
Troubleshooting procedure
If a failure symptom appears on the machine, select an appropriate troubleshooting No. according to the
following procedure, and go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when an action level is displayed on machine monitor:
If an action level appears on the machine monitor, display the failure code by using the abnormality record
display function (for electrical and mechanical systems) of the machine monitor (EMMS). (See [*1].)
Perform the corresponding troubleshooting classified in [Code display] mode according to the displayed
failure code.
a Each failure code appears "flashing" when the problem corresponding to it is detected. Even if a failure
code appears "lighting up" with the starting switch in ON, the problem corresponding to that failure code
has not necessarily been repaired (some problems can be detected by simply turning the starting
switch to ON position).
a If any failure code is recorded, be sure to perform the operation for reproducing it to see whether the
problem corresponding to it still remains as a problem or has been repaired (for the method of
reproducing the failure code, see the troubleshooting in [Code display]).
WA500-6 7
General information on troubleshooting
SEN00729-02 Classification and procedures of troubleshooting
8 WA500-6
General information on troubleshooting
Classification and procedures of troubleshooting SEN00729-02
WA500-6 9
General information on troubleshooting
SEN00729-02 Classification and procedures of troubleshooting
10 WA500-6
General information on troubleshooting
Information in troubleshooting table SEN00729-02
<Details of description>
q Procedure
1 Defective component
q Measuring location
a "Between A and B" means the measurement of voltage, resistance or oth-
ers between terminals A and B.
q Criteria to judge probable causes (normal value)
q Remarks for judgment
Open or short circuit in wiring <How to use troubleshooting sheet>
2 q Perform troubleshooting procedures in numerical order.
harness
q If the check result does not meet the criteria, the probable cause described
on the left column is the actual cause of the failure.
q If the check result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
Open circuit in wiring harness q Check that the failure is fixed after a failure was found and repaired.
3 (wire breakage or defective con- <Failures in wiring harness>
tact of connector) q Open circuit in wiring
The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or ma-
chine.
Ground fault in wiring harness
4 q Hot short circuit
(contact with ground circuit)
A harness not connected to the power circuit (24 V) contacts with the power
circuit.
q Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
Hot short circuit <Precautions for troubleshooting>
5
(contact with 24 V circuit) (1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless otherwise
specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
6 Short circuit in wiring harness male connectors.
q When "male" or "female" is indicated with a connector number, discon-
nect the connector, and connect T-adapter only to either male or femae
connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown
below unless otherwise specified.
7 Defective controller
q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.
WA500-6 11
General information on troubleshooting
SEN00729-02 Information in troubleshooting table
12 WA500-6
General information on troubleshooting
Troubleshooting method for disconnecting wiring harness of pressure SEN00729-02
a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the differences among the resistances measured and its own polarities. So troubleshooting must be
performed carefully.
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be different from each other, take several measurements. Cause of
the differences appears to be that the sensor may be charged by the tester. Take several measure-
ment in both steps 1 and 2. Take the fact into consideration this differences when determining
whether the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
WA500-6 13
General information on troubleshooting
SEN00729-02 Troubleshooting method for disconnecting wiring harness of pressure
14 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
WA500-6 15
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
16 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 17
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
18 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 19
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
20 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 21
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
22 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 23
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
24 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 25
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
26 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 27
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
28 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 29
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
30 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 31
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
32 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 33
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
34 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 35
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
36 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 37
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
38 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 39
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
40 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 41
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
42 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 43
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
44 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 45
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
46 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 47
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
48 WA500-6
General information on troubleshooting
Connection table for connector pin numbers SEN00729-02
WA500-6 49
General information on troubleshooting
SEN00729-02 Connection table for connector pin numbers
50 WA500-6
General information on troubleshooting
T- branch box and T- branch adapter table SEN00729-02
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
WA500-6 51
General information on troubleshooting
SEN00729-02 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
52 WA500-6
General information on troubleshooting
T- branch box and T- branch adapter table SEN00729-02
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
WA500-6 53
SEN00729-02
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
54
SEN00730-01
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 .............................................................................. 3
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
WA500-6 1
SEN00730-01 40 Troubleshooting
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
2 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 3
SEN00730-01 40 Troubleshooting
4 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 5
SEN00730-01 40 Troubleshooting
6 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 7
SEN00730-01 40 Troubleshooting
8 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 9
SEN00730-01 40 Troubleshooting
10 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 11
SEN00730-01 40 Troubleshooting
12 WA500-6
40 Troubleshooting SEN00730-01
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified.
WA500-6 13
SEN00730-01 40 Troubleshooting
Fuse box A
Fuse box B
14 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 15
SEN00730-01 40 Troubleshooting
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good
16 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 17
SEN00730-01 40 Troubleshooting
18 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 19
SEN00730-01 40 Troubleshooting
20 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 21
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SAL1 (Transmission controller system)
Contents of • When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the F ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • F travel is enabled, but R travel is disabled.
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).
• Method of reproducing failure code: Start engine.
22 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 23
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV F clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SALH (Transmission controller system)
Contents of
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31608, ECMV F DIR).
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
Related
40908, D-IN-25).
information
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
40908, D-IN-25).
• Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch F (forward)
24 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 25
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV R clutch When command current is OFF, fill signal is ON
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the R ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • The machine can travel in the R position, but cannot travel in the F position.
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
toring function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-26).
• Method of reproducing failure code: Start engine.
26 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 27
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV R clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SBLH (Transmission controller system)
Contents of • When R ECMV solenoid output is turned ON, R ECMV fill switch signal ON is not input.
trouble • Engine speed is below 500 rpm, and clutch does not mesh.
Action of • Judges that the R ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
toring function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-26).
• Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR
(directional) switch, or right FNR (directional) switch R (reverse)
28 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 29
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV 1st clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 1st ECMV fill switch signal is turned ON.
• Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31602, ECMV 1 DIR).
Related
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-27).
• Method of reproducing failure code: Start engine.
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard 3 harness (Contact with
value in normal ground circuit) Wiring harness between L03 (female) (7) – Resis-
Min. 1 Mz
state 1.SW (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (7) – 1st (1st speed) Max. 1 V
chassis ground Other than above 8 – 10 V
30 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 31
SEN00730-01 40 Troubleshooting
Failure code [15SELH] (ECMV 1st clutch: When command current is ON,
fill signal is OFF) 1
Action code Failure code ECMV 1st clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SELH (Transmission controller system)
Contents of
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 1st.
appears on
• When the 1st gear speed is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31602, ECMV 1 DIR).
Related • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-27).
• Method of reproducing failure code: Engine started + Manual/auto shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 1st
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
and standard ness (Disconnection or without turning starting switch ON.
3
value in normal defective contact of connec- Wiring harness between L03 (female) (7) – Resis-
tor) Max. 1 z
state 1.SW (female) (1) tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (7) – 1st (1st speed) Max. 1 V
chassis ground Other than above 8 – 10 V
32 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 33
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV 2nd clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SFL1 (Transmission controller system)
Contents of • When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch
trouble is not released.
• Turns the centralized warning lamp and alarm buzzer ON.
• Judges that the 2nd ECMV fill switch signal is turned ON.
Action of
• Holds 1st, 3rd, and 4th proportional solenoid outputs OFF.
controller
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31603, ECMV 2 DIR).
Related
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-28).
• Method of reproducing failure code: Start engine.
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard 3 harness (Contact with
value in normal ground circuit) Wiring harness between L03 (female) (13) – Resis-
Min. 1 Mz
state 2.SW (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (13) – 2nd (2nd speed) Max. 1 V
chassis ground Other than above 8 – 10 V
34 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 35
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV 2nd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SFLH (Transmission controller system)
Contents of
• When 2nd ECMV solenoid output is turned ON, 2nd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 2nd.
appears on
• When the 2nd gear speed is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31603, ECMV 2 DIR).
Related • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-28).
• Method of reproducing failure code: Engine started + Manual/auto shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 2nd
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
and standard 3 harness (Disconnection or
value in normal Wiring harness between L03 (female) (13) – Resis-
defective contact of connector) Max. 1 z
state 2.SW (female) (1) tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (13) – 2nd (2nd speed) Max. 1 V
chassis ground Other than above 8 – 10 V
36 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 37
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV 3rd: When command current is OFF, fill signal is ON
Trouble
E03 15SGL1 (Transmission controller system)
Contents of • When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 3rd ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31604, ECMV 3 DIR).
Related
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-29).
• Method of reproducing failure code: Start engine.
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard 3 harness (Contact with
value in normal ground circuit) Wiring harness between L03 (female) (3) – Resis-
Min. 1 Mz
state 3.SW (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (3) – 3rd (3rd speed) Max. 1 V
chassis ground Other than above 8 – 10 V
38 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 39
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV 3rd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SGLH (Transmission controller system)
Contents of • When 3rd ECMV solenoid output is turned ON, 3rd ECMV fill switch signal ON is not input.
trouble • Engine speed is below 500 rpm and clutch does not mesh.
Action of • Judges that the 3rd ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 3rd.
appears on
• When the 3rd gear speed is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31604, ECMV 3 DIR).
Related • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-29).
• Method of reproducing failure code: Engine started + Manual/auto shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 3rd
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
and standard 3 harness (Disconnection or
value in normal Wiring harness between L03 (female) (3) – Resis-
defective contact of connector) Max. 1 z
state 3.SW (female) (1) tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (3) – 3rd (3rd speed) Max. 1 V
chassis ground Other than above 8 – 10 V
40 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 41
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV 4th: When command current is OFF, fill signal is ON
Trouble
E03 15SHL1 (Transmission controller system)
Contents of • When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 4th ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to “N (Neutral)”.
Problem that
appears on • The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4 DIR).
Related
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-30).
• Method of reproducing failure code: Start engine.
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
and standard 3 harness (Contact with
value in normal ground circuit) Wiring harness between L03 (female) (2) – Resis-
Min. 1 Mz
state 4.SW (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (2) – 4th (4th speed) Max. 1 V
chassis ground Other than above 8 – 10 V
42 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 43
SEN00730-01 40 Troubleshooting
Action code Failure code ECMV 4th: When command current is ON, fill signal is OFF
Trouble
E01 15SHLH (Transmission controller system)
Contents of
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 4th.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
• This failure code may be displayed just after transmission oil was changed.
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4).
Related • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-30).
• Method of reproducing failure code: Engine started + Manual/auto shift selector switch to MANUAL +
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to
F (forward) or R (reverse) + Shift lever 4th
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
and standard 3 harness (Disconnection or
value in normal Wiring harness between L03 (female) (2) – Resis-
defective contact of connector) Max. 1 z
state 4.SW (female) (1) tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
4
controller • Set the FNR (directional) lever, joystick steering FNR (directional)
switch, or right FNR (directional) switch to F (forward) or R
(reverse).
L03 Shift lever Voltage
Between (2) – 4th (4th speed) Max. 1 V
chassis ground Other than above 8 – 10 V
44 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 45
SEN00730-01 40 Troubleshooting
46 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 47
SEN00730-01 40 Troubleshooting
48 WA500-6
40 Troubleshooting SEN00730-01
WA500-6 49
SEN00730-01
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 08-06 (01)
50
SEN00731-03
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 2
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
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
WA500-6 1
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03
2 WA500-6
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03
WA500-6 3
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [2G43ZG] Rear accumulator: Low oil pressure
4 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [2G43ZG] Rear accumulator: Low oil pressure SEN00731-03
WA500-6 5
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree
6 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree SEN00731-03
WA500-6 7
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [44K0L4] Bucket positioner: ON/OFF signals disagree
8 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [AA1ANX] Air cleaner: Clogging SEN00731-03
WA500-6 9
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [AA1ANX] Air cleaner: Clogging
10 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [AB00L6] Alternator: Signal disagrees with operating state of SEN00731-03
Action code Failure code Alternator: Signal does not match engine running or stopped state
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Turns charge circuit abnormality caution lamp ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
• After engine start operation, after the starting switch is simply turned ON, the service meter
appears on
advances.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information
• Method of reproducing failure code: Turn starting switch ON.
WA500-6 11
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [AB00L6] Alternator: Signal disagrees with operating state of
12 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [AB00MA] Alternator: Malfunction SEN00731-03
WA500-6 13
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [AB00MA] Alternator: Malfunction
14 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [B@BAZG] Low engine oil pressure SEN00731-03
WA500-6 15
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [B@BAZK] Engine oil: Low level
16 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [B@BAZK] Engine oil: Low level SEN00731-03
WA500-6 17
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [B@BCNS] Coolant: Overheating
18 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [B@BCNS] Coolant: Overheating SEN00731-03
WA500-6 19
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [B@BCZK] Coolant: Low level
20 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [B@BCZK] Coolant: Low level SEN00731-03
WA500-6 21
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [b@CENS] Torque converter oil: Overheating
22 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [B@CENS] Torque converter oil: Overheating SEN00731-03
WA500-6 23
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [B@GAZK] Battery electrolyte: Low level
24 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [B@HANS] Hydraulic oil: Overheating SEN00731-03
WA500-6 25
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA111] Abnormality in engine controller
26 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA111] Abnormality in engine controller SEN00731-03
WA500-6 27
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA111] Abnormality in engine controller
28 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA115] Engine Ne or Bkup speed sensor error SEN00731-03
Detail of failure • Abnormality occurred in the signal of Ne and Bkup speed sensor circuits at the same time.
Action of con- • Stops the engine.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on • The engine does not start. (if engine has been stopped.)
machine • Engine stops. (if engine has been running.)
Related infor-
• Method of reproducing failure code: Start engine.
mation
WA500-6 29
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA122] Charge (boost) pressure sensor high error
Detail of failure • High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- • Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output drops.
machine
• The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36502 (V)).
• Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
Related infor-
checked with monitoring function (Code: 36500 (kPa)).
mation
• Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal con-
dition.
30 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA122] Charge (boost) pressure sensor high error SEN00731-03
WA500-6 31
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA123] Charge (boost) pressure sensor low error
Detail of failure • Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- • Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output drops.
machine
• The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36502 (V)).
• Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
checked with monitoring function (Code: 36500 (kPa)).
Related infor-
• Method of reproducing failure code: Turn starting switch to ON position.
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
adapter).
• If sensor connector is disconnected, this code is displayed.
32 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA123] Charge (boost) pressure sensor low error SEN00731-03
WA500-6 33
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA131] Throttle sensor high error
34 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA131] Throttle sensor high error SEN00731-03
WA500-6 35
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA131] Throttle sensor high error
36 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA132] Throttle sensor low error SEN00731-03
Detail of failure • Accelerator pedal signal circuit of throttle sensor detected abnormally low voltage.
Action of con- • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• The engine does not reach full speed.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701).
Related infor-
• The input voltage from the throttle sensor can be checked with the monitoring function (Code:
mation
31707).
• Method of reproducing failure code: Turn starting switch to ON position.
WA500-6 37
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA132] Throttle sensor low error
38 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA132] Throttle sensor low error SEN00731-03
WA500-6 39
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA135] Engine oil pressure sensor high error
Action code Failure code Eng Oil Press Sensor High Error
Failure
E02 CA135 (Engine controller system)
Detail of failure • High voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
• Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
troller
Problem on
machine
• Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
• Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
40 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA135] Engine oil pressure sensor high error SEN00731-03
WA500-6 41
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA141] Engine oil pressure sensor low error
Action code Failure code Eng Oil Press Sensor Low Error
Failure
E02 CA141 (Engine controller system)
Detail of failure • Low voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
• Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
troller
Problem on
machine
• Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
• Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
42 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA141] Engine oil pressure sensor low error SEN00731-03
WA500-6 43
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA144] Coolant temperature sensor high error
Detail of failure • High voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
• Sets coolant temperature to fixed temperature (90 °C), and allows for operation.
troller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function. (Code: 04104 (°C))
Related infor-
• Method of reproducing failure code: Turn starting switch to ON position.
mation
• This failure code is displayed if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).
44 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA144] Coolant temperature sensor high error SEN00731-03
WA500-6 45
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA145] Coolant temperature sensor low error
Detail of failure • Low voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
• Sets coolant temperature to fixed temperature (90 °C), and allows for operation.
troller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04104 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
Related infor-
function. (Code: 04104 ( °C))
mation
• Method of reproducing failure code: Turn starting switch to ON position.
• If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.
3 Short circuit in wiring harness Between ENG (female) (15) and (38) (Coolant tem-
perature: Min. 0 °C) 700 z –
Resistance
a Use "coolant temperature -Resistance character- 37 kz
istics" table shown above as resistance criteria.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and TWTR, and connect T-adapter to female
4 side of ENG.
(Contact with ground circuit)
Between ENG (female) (15) and ground Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective. (Since
5 Defective engine controller
failure is in it, troubleshooting cannot be performed.)
46 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA145] Coolant temperature sensor low error SEN00731-03
WA500-6 47
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA153] Charge (boost) temperature sensor high error
Action code Failure code Charge (Boost) temperature sensor signal voltage is too high.
Failure
E01 CA153 (Engine controller system)
Detail of failure • High voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con- • Set charge temperature to fixed temperature (70 °C), and allow for operation.
troller • Limits engine output and allows engine to run.
Problem on • Engine does not start easily at low temperature.
machine • Engine output drops.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked by
using monitoring function. (Code: 18500 ( °C))
Related infor-
• Method of reproducing failure code: Turn starting switch to ON position.
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.
48 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA153] Charge (boost) temperature sensor high error SEN00731-03
WA500-6 49
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA154] Charge (boost) temperature sensor low error
Action code Failure code Charge (Boost) temperature sensor signal volatge too low
Failure
E01 CA154 (Engine controller system)
Detail of failure • Low voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con- • Set charge temperature to fixed temperature (70 °C), and allow for operation.
troller • Limits engine output and allows engine to run.
Problem on • Engine does not start easily at low temperature.
machine • Engine output drops.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked by
Related infor-
using monitoring function. (Code: 18500 ( °C))
mation
• Method of reproducing failure code: Turn starting switch to ON position.
• If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA153] for "High Error" is displayed.
50 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA154] Charge (boost) temperature sensor low error SEN00731-03
WA500-6 51
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA187] Sensor power supply 2 low error
52 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA187] Sensor power supply 2 low error SEN00731-03
WA500-6 53
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA187] Sensor power supply 2 low error
54 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA187] Sensor power supply 2 low error SEN00731-03
WA500-6 55
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA221] Atmospheric pressure sensor high error
Detail of failure • High voltage was detected in ambient pressure sensor signal circuit.
Action of con- • Takes it that ambient pressure value is default value (52.44 kPa {0.53 kg/cm2}), and allows engine
troller to run.
Problem on
• Engine output drops.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37402
(V)).
Related infor-
• Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
mation
(Code: 37400 (kPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
56 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA221] Atmospheric pressure sensor high error SEN00731-03
WA500-6 57
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA222] Atmospheric pressure sensor low error
Detail of failure • Low voltage was detected ambient pressure sensor signal circuit.
Action of con- • Takes it that ambient pressure value is default value(52.44 kPa {0.53 kg/cm2}), and allows engine to
troller run.
Problem on
• Engine output drops.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37402
(V)).
• Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
(Code: 37400 (kPa)).
Related infor-
• Method of reproducing failure code: Turn starting switch to ON position.
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
adapter).
• If sensor connector is disconnected, this code is displayed.
58 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA222] Atmospheric pressure sensor low error SEN00731-03
WA500-6 59
Troubleshooting by failure code (Display of code), Part 2
SEN00731-03 Failure code [CA227] Sensor power supply 2 high error
Action code Failure code Sensor power supply circuit voltage is too high
Failure
E03 CA227 (Engine controller system)
* EGR inlet pressure sensor is abolished from serial No.:55121 (engine serial No.:530880)
60 WA500-6
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA227] Sensor power supply 2 high error SEN00731-03
WA500-6 61
SEN00731-03
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
62
SEN00732-04
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 3
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
WA500-6 1
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04
2 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA234] Engine overspeed SEN00732-04
WA500-6 3
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA238] Ne speed sensor power supply error
4 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA238] Ne speed sensor power supply error SEN00732-04
WA500-6 5
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA263] Fuel Temp Sensor High Error
6 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA263] Fuel Temp Sensor High Error SEN00732-04
WA500-6 7
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA265] Fuel Temp Sensor Low Error
8 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA265] Fuel Temp Sensor Low Error SEN00732-04
WA500-6 9
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA271] PCV1 Short circuit
Detail of failure • Short circuit was detected in supply pump PCV1 circuit.
Action of con-
• Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on
• Engine output drops.
machine
Related infor- • Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while engine is run-
mation ning. However, it cannot be measured with multimeter since it is pulse voltage.
10 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA272] PCV1 Disconnection SEN00732-04
WA500-6 11
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA273] PCV2 Short circuit
Detail of failure • Short circuit was detected in supply pump PCV2 circuit.
Action of con-
• Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on
• Engine output drops.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
• While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But it
mation
is pulse voltage and cannot be measured by using multimeter.
12 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA274] PCV2 Disconnection SEN00732-04
WA500-6 13
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA322] Injector #1 open/short error
14 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA322] Injector #1 open/short error SEN00732-04
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
X: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.
WA500-6 15
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA323] Injector #5 open/short error
16 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA323] Injector #5 open/short error SEN00732-04
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
X: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.
WA500-6 17
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA324] Injector #3 open/short error
Action code Failure code Injector #3(L#3) open /short circuit error
Failure
E03 CA324 (Engine controller system)
18 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA324] Injector #3 open/short error SEN00732-04
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
X: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.
WA500-6 19
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA325] Injector #6 open/short error
Action code Failure code Injector #6 (L#6) open / short circuit error
Failure
E03 CA325 (Engine controller system)
Detail of failure • Opening or short circuit was detected in drive circuit of No. 6 injector.
Action of con-
• Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on • Engine output drops.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related infor-
• While engine is running normally, approximately 70 V of pulse voltage is applied to injector (positive)
mation
side. But it is pulse voltage and cannot be measured by using multimeter.
20 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA325] Injector #6 open/short error SEN00732-04
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
X: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.
WA500-6 21
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA331] Injector #2 open/short error
22 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA331] Injector #2 open/short error SEN00732-04
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
X: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.
WA500-6 23
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA332] Injector #4 open/short error
Action code Failure code Injector #4 (L#4) open / short circuit error
Failure
E03 CA332 (Engine controller system)
24 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA332] Injector #4 open/short error SEN00732-04
Q: Injector wiring harness (H) is in good condition being laid close to injector (N)
X: Injector wiring harness (H) is in bad condition without being laid close to injector (N)
a: Injector wiring harness (H) may interfere with rocker arm.
WA500-6 25
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA342] Calibration code inconsistency
26 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA351] Injectors drive circuit error SEN00732-04
WA500-6 27
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA352] Sens Supply 1 Volt Low Error
28 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA352] Sens Supply 1 Volt Low Error SEN00732-04
WA500-6 29
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA386] Sensor power supply 1 high error
Action code Failure code Sensor power supply 1 voltage is too high
Failure
E03 CA386 (Engine controller system)
30 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA431] Idle validation switch error SEN00732-04
Detail of failure • Signals 1 and 2 (IVS1 and IVS2) from idle validation switch are unusual.
Action of
• Runs engine at the throttle opening based on signal from throttle sensor.
controller
Problem on
machine
• Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function.
(Code: ENGINE, 18300, IVS 1)
Related
• Input (ON/OFF) from the idle validation switch 2 can be checked by using monitoring function.
information
(Code: ENGINE, 18301, IVS 2)
• Method of reproducing failure code: Turn starting switch to ON position.
WA500-6 31
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA431] Idle validation switch error
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Signal 1: Signal voltage of idle validation switch 1
...Dash line
Signal 2: Signal voltage of idle validation switch 2
...Bold line
32 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA431] Idle validation switch error SEN00732-04
WA500-6 33
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA432] Idle validation action error
Detail of failure • Idle validation switch signal and throttle sensor signal are inconsistent.
Action of • Operates at position of throttle of accelerator pedal (throttle sensor).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on • Engine speed does not rise from low idle.
machine • Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
• Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function.
(Code: ENGINE, 18300, IVS 1)
• Input (ON/OFF) from the idle validation switch 2 can be checked by using monitoring function.
(Code: ENGINE, 18301, IVS 2)
Related
• Input voltage from the throttle sensor can be checked by using monitoring function.
information
(Code: ENGINE, 31707, THROTTLE POS)
• Accelerator pedal position sensed by the throttle sensor can be checked by using monitoring func-
tion. (Code: ENGINE, 31701, THROTTLE POS)
• Method of reproducing failure code: Turn starting switch to ON position.
34 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA432] Idle validation action error SEN00732-04
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Signal 1: Signal voltage of idle validation switch 1
...Dash line
Signal 2: Signal voltage of idle validation switch 2
...Bold line
WA500-6 35
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA432] Idle validation action error
36 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA441] Battery voltage low error SEN00732-04
Detail of failure • Low voltage (5.7 V or below) is detected in power supply circuit.
Action of con-
• Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on • Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
• Method of reproducing failure code: Turn starting switch to ON position.
mation
WA500-6 37
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA442] Battery voltage high error
Detail of failure • High voltage (36 V or higher) appears in power supply circuit.
Action of con-
• Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on
• Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
• Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03200
mation
(V))
38 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA449] Common rail pressure high error 2 SEN00732-04
• Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set
Detail of failure
maximum level).
Action of con-
• Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on • Engine output drops.
machine • Turns the centralized warning lamp and alarm buzzer ON.
• Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
• Method of reproducing failure code: Start engine.
WA500-6 39
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA451] Rail Press Sensor High Error
40 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA451] Rail Press Sensor High Error SEN00732-04
WA500-6 41
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA452] Rail Press Sensor Low Error
42 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA452] Rail Press Sensor Low Error SEN00732-04
WA500-6 43
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA553] Common rail pressure high error 1
• Abnormal high pressure (higher than set pressure) was detected more than 10 seconds in the signal
Detail of failure
circuit of common rail pressure sensor.
Action of con-
• Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
• Method of reproducing failure code: Start engine.
44 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA554] Common rail pressure sensor in range error SEN00732-04
Action code Failure code Common rail pressure sensor signal voltage is beyond input range
Failure
E03 CA554 (Engine controller system)
Detail of failure • Signal voltage of common rail pressure sensor is beyond input range.
Action of con- • Limits engine output (limits common rail pressure) and allows engine to run.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output drops.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring func-
mation
tion (Code: 36400 (MPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
WA500-6 45
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA559] Supply pump pressure very low error 1
Detail of failure • Supply pump does not pressure feed fuel (level1).
Action of con- • Limits common rail pressure.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output drops.
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
Related infor-
function (Code: 36400 (MPa)).
mation
• Method of reproducing failure code: Start engine.
46 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA559] Supply pump pressure very low error 1 SEN00732-04
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
WA500-6 47
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA559] Supply pump pressure very low error 1
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle rpm 625 ± 25
01002 Engine speed High idle rpm 2,150 ± 50
Full stall (P-mode) rpm 1,800 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 147
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 1,100}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Standard value Measured
Function Cut-out cylinder Check conditions Unit Good Bad
(Reference value) value
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
Cylinder 3 Low idle rpm — — —
cut-out
Cylinder 4 Low idle rpm — — —
function
Cylinder 5 Low idle rpm — — —
Cylinder 6 Low idle rpm — — —
48 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA559] Supply pump pressure very low error 1 SEN00732-04
WA500-6 49
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA689] Engine Ne speed sensor error
50 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA689] Engine Ne speed sensor error SEN00732-04
q Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of fly-
wheal, and the engine controller calculates the engine speed and phase.
WA500-6 51
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA731] Engine Bkup speed sensor phase error
Action code Failure code Engine Bkup speed sensor phase error
Failure
E03 CA731 (Engine controller system)
52 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA757] All continuous data lost error SEN00732-04
Action code Failure code All engine controller data lost error
Failure
E03 CA757 (Engine controller system)
WA500-6 53
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA778] Engine Bkup speed sensor error
54 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA778] Engine Bkup speed sensor error SEN00732-04
WA500-6 55
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA778] Engine Bkup speed sensor error
56 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA778] Engine Bkup speed sensor error SEN00732-04
WA500-6 57
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1228] EGR valve servo error 1
58 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1625] EGR valve servo error 2 SEN00732-04
WA500-6 59
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1626] Bypass valve solenoid current high error
Action code Failure code Bypass valve solenoid current high error
Failure
E03 CA1626 (Engine controller system)
Detail of failure • High current was detected in drive circuit of bypass valve solenoid.
• Limits output and continues operation.
Action of
• Stops outputting current to EGR valve and bypass valve (closes EGR valve and bypass valve).
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
60 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1626] Bypass valve solenoid current high error SEN00732-04
WA500-6 61
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1627] Bypass valve solenoid current low error
Action code Failure code Bypass valve solenoid drive circuit disconnection error
Failure
E03 CA1627 (Engine controller system)
Detail of failure • Disconnection error was detected in drive circuit of bypass valve solenoid.
• Limits output and continues operation.
Action of • Close EGR and bypass valves.Stops outputting current to EGR valve and bypass valve (closes
controller EGR valve and bypass valve).
• Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
62 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1627] Bypass valve solenoid current low error SEN00732-04
WA500-6 63
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1628] Bypass Valve Servo Error 1
64 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1629] Bypass Valve Servo Error 2 SEN00732-04
WA500-6 65
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1631] Bypass valve lift sensor high error
Action code Failure code Bypass valve lift sensor high error
Failure
E03 CA1631 (Engine controller system)
Detail of failure • Bypass valve lift sensor circuit is abnormally high.
• Limits output and continues operation.
Action of
• Stops outputting current to EGR valve and bypass valve (closes EGR valve and bypass valve).
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output lowers.
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202).
• Method of reproducing failure code: Start engine
Defective sensor
2 power supply sys- If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
tem
66 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1631] Bypass valve lift sensor high error SEN00732-04
WA500-6 67
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1632] Bypass valve lift sensor low error
Action code Failure code Bypass valve lift sensor low error
Failure
E03 CA1632 (Engine controller system)
Detail of failure • Bypass valve lift sensor circuit is abnormally low.
• Limits output and continues operation.
Action of
• Stops outputting current to EGR valve and bypass valve (closes EGR valve and bypass valve).
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output lowers.
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202).
• Method of reproducing failure code: Start engine
If failure code [CA187] (Ground fault in sensor power supply line) or [CA227] is displayed,
perform troubleshooting for it first.
Defective sensor
2 power supply sys- 1. Turn starting switch to OFF position.
tem 2. Disconnect connector SBP and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between SBP (female) (1) and (2) Power supply Voltage 4.75 – 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors SBP and ENG, and connect T-adapters to each female side.
a If power supply voltage in check on cause 2 is normal, this
Open circuit in wir-
check is not required. Resistance Max. 1 z
ing harness
Between ENG (female) (37) and SBP (female) (1)
3 (wire breakage or
a If power supply voltage in check on cause 2 is normal, this
defective contact of
check is not required. Resistance Max. 1 z
connector)
Between ENG (female) (47) and SBP (female) (2)
Between ENG (female) (29) and SBP (female) (3) and, between
Resistance Max. 1 z
ENG (female) (29) and SBP (female) (4), (Sensor output)
Ground fault in wir- 1. Turn starting switch to OFF position.
ing harness 2. Disconnect connectors ENG and SBP, and connect T-adapters to either female side.
4
(Contact with Between ENG (female) (29) and ground, or between SBP
Resistance Min. 1 Mz
ground circuit) (female) (3) and ground
1. Turn starting switch to OFF position.
Short circuit in wir- 2. Disconnect connectors ENG and SBP, and connect T-adapters to either female side.
5
ing harness Between ENG (female) (29) and (47), or between SBP (female)
Resistance Min. 1 Mz
(2) and (3)
a If cause items 1 - 5 are not the cause for the trouble and check result of cause 6 is abnor-
mal, sensor is defective.
Defective bypass 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG or SBP.
valve lift sensor
3. Turn starting switch to ON position.
Between ENG (29) and (47), or between SBP (3) and (2) Voltage 0.5 – 4.5 V
Defective engine If no abnormality is found by the above checks, the engine controller is defective. (Since this
7
controller is an internal failure, troubleshooting cannot be performed.)
68 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1632] Bypass valve lift sensor low error SEN00732-04
WA500-6 69
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1633] KOMNET datalink timeout error
• Engine controller detected communication error in CAN (KOMNET) communication circuit between
Detail of failure
engine controller and power train controller, work equipment controller or machine monitor.
Action of con- • Controls engine in default mode, and holds state at the time of abnormally.
troller • If cause of failure disappears, machine becomes normal by itself.
• Information may not be transmitted normally through CAN (KOMNET) communication and machine
Problem on
may not operate normally.
machine
(Trouble phenomenon depends on failed section.)
Related infor-
• Method of reproducing failure code: Start engine.
mation
70 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1633] KOMNET datalink timeout error SEN00732-04
WA500-6 71
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor1
Action code Failure code Abnormally low signal in EGR inlet pressure sensor
Trouble
E01 CA1642 (Engine controller system)
Contents of
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally low.
trouble
Action of • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller • Limits engine output and continues operation.
Problem that
appears on • Engine output lowers.
machine
a EGR inlet pressure sensor is applied to only machines Serial No. up to 55120 (engine serial No.: up
to 530879).
• Signal voltage from the EGR inlet pressure sensor can be checked with the monitoring function
Related
(Code: 18001 (V)).
information
• Pressure sensed by EGR inlet pressure sensor can be checked with monitoring function (Code:
18000 (kPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
72 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sen- SEN00732-04
WA500-6 73
Troubleshooting by failure code (Display of code), Part 3
SEN00732-04 Failure code [CA1653] Abnormally high signal in EGR inlet pressure sen-
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor 1
Action code Failure code Abnormally high signal in EGR inlet pressure sensor
Trouble
E01 CA1653 (Engine controller system)
Contents of
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally high.
trouble
Action of • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller • Limits engine output and continues operation.
Problem that
appears on • Engine output lowers.
machine
a EGR inlet pressure sensor is applied to only machines Serial No. up to 55120 (engine serial No.: up
to 530879).
• Signal voltage from the EGR inlet pressure sensor can be checked with the monitoring function
Related
(Code: 18001 (V)).
information
• Pressure sensed by EGR inlet pressure sensor can be checked with monitoring function (Code:
18000 (kPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
74 WA500-6
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sen- SEN00732-04
WA500-6 75
SEN00732-04
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
76
SEN00733-04
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 4
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................... 4
Failure code [CA2186] Throttle sensor power supply low error ...................................................................... 6
Failure code [CA2249] Supply pump pressure very low error 2 ..................................................................... 8
Failure code [CA2271] EGR valve lift sensor high error ............................................................................... 10
Failure code [CA2272] EGR valve lift sensor low error................................................................................. 12
Failure code [CA2351] EGR valve solenoid operation short circuit .............................................................. 14
Failure code [CA2352] EGR valve solenoid operation disconnect ............................................................... 16
Failure code [CA2555] Intake air heater relay open circuit error .................................................................. 18
Failure code [CA2556] Intake air heater relay short circuit error .................................................................. 20
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit ................................................... 22
Failure code [D191KA] Joystick steering neutral safety relay: Disconnection .............................................. 24
Failure code [D191KB] Joystick steering neutral safety relay: Short circuit.................................................. 26
Failure code [D192KA] ECSS solenoid: Disconnection ................................................................................ 28
Failure code [D192KB] ECSS solenoid: Short circuit.................................................................................... 29
WA500-6 1
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04
Failure code [D192KY] ECSS solenoid: Short circuit with power supply line................................................ 30
Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection................................................. 32
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit .................................................... 34
Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit with power supply line ................ 36
Failure code [D5ZHKA] Terminal C signal: Disconnection ............................................................................ 38
Failure code [D5ZHKB] Terminal C signal: Short circuit................................................................................ 42
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit..................................................... 44
Failure code [D5ZHL6] Terminal C signal: Signal does not match engine running or stopped state ............ 46
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree.................................................... 49
Failure code [DAF3KK] Machine monitor: Low source voltage (input).......................................................... 52
Failure code [DAF5KP] Machine monitor: Low output voltage...................................................................... 54
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in
target component system)......................................................................................................................... 56
Failure code [DAQ0KK] Transmission controller: Low source voltage.......................................................... 57
Failure code [DAQ0KT] Transmission controller: Abnormality in controller .................................................. 60
Failure code [DAQ2KK] Transmission controller load power supply line: Low source voltage (input) .......... 61
Failure code [DAQ9KQ] Transmission controller model selection: Disagreement of model selection signals
.................................................................................................................................................................. 64
2 WA500-6
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04
WA500-6 3
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2185] Throttle sensor supply voltage high error
Action code Failure code Throttle sensor power supply voltage is high
Failure
E03 CA2185 (Engine controller system)
Detail of failure • High voltage (5.25 V or higher) is detected in throttle sensor power supply circuit.
Action of • Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle when
controller pedal is depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine • Turns the centralized warning lamp and alarm buzzer ON.
Related
• Method of reproducing failure code: Turn starting switch to ON position.
information
4 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2185] Throttle sensor supply voltage high error SEN00733-04
WA500-6 5
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2186] Throttle sensor power supply low error
Action code Failure code Throttle sensor power supply voltage is low
Failure
E03 CA2186 (Engine controller system)
Detail of failure • Low voltage is detected in throttle sensor power supply circuit.
Action of • Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle when
controller accelerator pedal is depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine • Turns the centralized warning lamp and alarm buzzer ON.
Related
• Method of reproducing failure code: Turn starting switch to ON position.
information
6 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2186] Throttle sensor power supply low error SEN00733-04
WA500-6 7
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2249] Supply pump pressure very low error 2
Detail of failure • No-pressure feed error (level 2) in supply pump was detected.
Action of con- • Limits common rail pressure.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on
• Engine output drops.
machine
• The signal voltage from the common rail pressure sensor can be checked with the monitoring func-
tion (Code: 36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
• Method of reproducing failure code: Start engine.
8 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2249] Supply pump pressure very low error 2 SEN00733-04
WA500-6 9
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2271] EGR valve lift sensor high error
Defective sensor
2 power supply sys- If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
tem
10 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2271] EGR valve lift sensor high error SEN00733-04
WA500-6 11
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2272] EGR valve lift sensor low error
If failure code [CA187] (Ground fault in sensor power supply line) or [CA227] is displayed,
perform troubleshooting for it first.
Defective sensor
2 power supply sys- 1. Turn starting switch to OFF position.
tem 2. Disconnect connector SEGR and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between SEGR (female) (1) and (2) Power supply Voltage 4.75 – 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors SEGR and ENG, and connect T-adapters to each female side.
a If power supply voltage in check on cause 2 is normal, this
Open circuit in wir- check is not required. Resistance Max. 1 z
ing harness Between ENG (female) (37) and SEGR (female) (1)
3 (wire breakage or a If power supply voltage in check on cause 2 is normal, this
defective contact of check is not required. Resistance Max. 1 z
connector) Between ENG (female) (47) and SEGR (female) (2)
Between ENG (female) (19) and SEGR (female) (3) and,
between ENG (female) (19) and SEGR (female) (4), (Sensor Resistance Max. 1 z
output)
Ground fault in wir- 1. Turn starting switch to OFF position.
ing harness 2. Disconnect connectors ENG and SEGR, and connect T-adapters to either female side.
4
(Contact with Between ENG (female) (19) and ground, or between SEGR
Resistance Min. 1 Mz
ground circuit) (female) (3) and ground
1. Turn starting switch to OFF position.
Short circuit in wir- 2. Disconnect connectors ENG and SEGR, and connect T-adapters to either female side.
5
ing harness Between ENG (female) (19) and (47), or between SEGR
Resistance Min. 1 Mz
(female) (2) and (3)
a If cause items 1 - 5 are not the cause for the trouble and check result of cause 6 is abnor-
mal, sensor is defective.
Defective EGR 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG or SEGR.
valve lift sensor
3. Turn starting switch to ON position.
Between ENG (19) and (47), or between SEGR (3) and (2) Voltage 0.5 – 4.5 V
Defective engine If no abnormality is found by the above checks, the engine controller is defective. (Since this
7
controller is an internal failure, troubleshooting is impossible.)
12 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2272] EGR valve lift sensor low error SEN00733-04
WA500-6 13
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2351] EGR valve solenoid operation short circuit
14 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2351] EGR valve solenoid operation short circuit SEN00733-04
WA500-6 15
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2352] EGR valve solenoid operation disconnect
16 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2352] EGR valve solenoid operation disconnect SEN00733-04
WA500-6 17
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2555] Intake air heater relay open circuit error
Failure code [CA2555] Intake air heater relay open circuit error 1
Action code Failure code Intake air heater relay open circuit
Failure
E01 CA2555 (Engine controller system)
Detail of failure • Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
• None in particular
troller
Problem on • Intake air heater does not work (degraded starting performance at low temperature and emission
machine of white smokes)
• Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function. (Code: 04104 (°C))
Related infor- • Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
mation -5 °C)
• Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheat relay L106.
18 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2555] Intake air heater relay open circuit error SEN00733-04
WA500-6 19
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [CA2556] Intake air heater relay short circuit error
Failure code [CA2556] Intake air heater relay short circuit error 1
Action code Failure code Intake air heater relay short circuit
Failure
E01 CA2556 (Engine controller system)
Detail of failure • Short circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
• None in particular
troller
Problem on • Intake air heater does not work (degraded starting performance at low temperature and emission of
machine white smokes)
• Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function. (Code: 04104 (°C))
Related infor- • Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
mation -5 °C)
• Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheat relay L106.
20 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [CA2556] Intake air heater relay short circuit error SEN00733-04
WA500-6 21
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit
Action code Failure code Backup lamp relay: Disconnection or short circuit
Trouble
E01 D160KZ (Transmission controller system)
Contents of • Since the backup lamp relay output system is disconnection or shorted, signals are not output to the
trouble backup relay.
Action of • Turns the output to the backup lamp relay OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Backup lamp does not light up.
appears on
• Backup buzzer does not sound.
machine
Related • Method of reproducing failure code: Turn starting switch ON and set FNR (directional) lever, joystick
information steering FNR (directional) switch, or right FNR (directional) switch to R (reverse).
22 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D160KZ] Backup lamp relay: Disconnection or short circuit SEN00733-04
WA500-6 23
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D191KA] Joystick steering neutral safety relay: Disconnec-
Action code Failure code Joystick steering neutral safety relay: Disconnection
Trouble
E01 D191KA (Work equipment controller system)
Contents of • Signals are not output to neutral safety relay due to disconnection of joystick steering neutral safety
trouble relay output system.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that • While operating the joystick steering, engine can be started (Steering moves immediately after
appears on engine started.).
machine • Engine can be started while joystick or right FNR switch is not in N (neutral).
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted
(initial setting).
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
Related
(Code: 40954, D-OUT-20).
information
• Machine with joystick steering only
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering
(engine stopped state)
24 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D191KA] Joystick steering neutral safety relay: Disconnec- SEN00733-04
WA500-6 25
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D191KB] Joystick steering neutral safety relay: Short circuit
Action code Failure code Joystick steering neutral safety relay: Short circuit
Trouble
E01 D191KB (Work equipment controller system)
Contents of • Signals are not output to joystick steering neutral safety relay due to grounding fault in joystick
trouble steering neutral safety relay output system.
Action of • Turns the output to the joystick steering neutral safety relay OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • While operating the joystick steering, engine can be started (Steering moves immediately after
appears on engine started.).
machine • Engine can be started while joystick or right FNR switch is not in N (neutral).
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted
(initial setting).
• Work equipment controller does not output signals to joystick steering neutral safety relay while out-
putting a failure code.
Related
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
information
(Code: 40954, D-OUT-20).
• Machine with joystick steering only
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation
(engine stopped state)
26 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D191KB] Joystick steering neutral safety relay: Short circuit SEN00733-04
WA500-6 27
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D192KA] ECSS solenoid: Disconnection
28 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D192KB] ECSS solenoid: Short circuit SEN00733-04
Action code Failure code ECSS (travel damper) solenoid: Short circuit
Trouble
E01 D192KB (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the chassis ground, abnormal current flowed when
trouble ECCS solenoid output is ON
Action of • Turns the output to the ECSS solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The ECSS does not operate.
appears on
• The wiring harness or controller may be burnt out.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code:
93300 ECSS V DIR).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn starting switch ON + Travel dumper switch ON + non-1st
speed
WA500-6 29
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D192KY] ECSS solenoid: Short circuit with power supply line
Failure code [D192KY] ECSS solenoid: Short circuit with power supply
line 1
Action code Failure code ECSS (travel damper) solenoid: Short circuit with power supply line
Trouble
E01 D192KY (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the power source, abnormal voltage was applied
trouble when ECSS solenoid output was turned OFF.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • ECCS keeps operating.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code:
Related 93300 ECSS V DIR).
information • Applicable only to ECSS specification machines (if equipped)
• Method of reproducing failure code: Turn starting switch ON.
30 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D192KY] ECSS solenoid: Short circuit with power supply SEN00733-04
WA500-6 31
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D193KA] Joystick steering solenoid cut relay: Disconnection
Action code Failure code Joystick steering solenoid cut relay: Disconnection
Trouble
E03 D193KA (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to disconnection of joystick steering
trouble solenoid cut relay output system.
• Stops outputting the signal to the joystick steering left-right EPC solenoid.
Action of • Turns the output to the joystick steering cut relay OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the moni-
toring function (Code: 40953, D-OUT-8).
Related
• Machine with joystick steering only
information
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation
(engine stopped state)
32 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D193KA] Joystick steering solenoid cut relay: Disconnec- SEN00733-04
WA500-6 33
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit 1
Action code Failure code Joystick steering solenoid cut relay: Short circuit
Trouble
E03 D193KB (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to grounding fault in joystick steer-
trouble ing solenoid cut relay output system.
• Stops the output to the joystick steering left-right EPC solenoid.
Action of • Turns the output to the joystick steering cut relay OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the moni-
toring function (Code: 40953, D-OUT-8).
Related
• Machine with joystick steering only
information
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation
(engine stopped state)
34 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D193KB] Joystick steering solenoid cut relay: Short circuit SEN00733-04
WA500-6 35
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit
Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit
with power supply line 1
Action code Failure code Joystick steering solenoid cut relay: Short circuit with power supply
Trouble line
E03 D193KY (Work equipment controller system)
Contents of • Signals are not output to joystick steering solenoid cut relay due to hot short circuit in joystick steer-
trouble ing solenoid cut relay output system.
• Stops the output to the joystick steering left-right EPC solenoid.
Action of • Stops the output to the joystick steering cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the moni-
toring function (Code: 40953, D-OUT-8).
Related
• Machine with joystick steering only
information
• Method of reproducing failure code: Turn the starting switch ON and joystick steering operation
(engine stopped state)
36 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D193KY] Joystick steering solenoid cut relay: Short circuit SEN00733-04
WA500-6 37
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D5ZHKA] Terminal C signal: Disconnection
38 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D5ZHKA] Terminal C signal: Disconnection SEN00733-04
WA500-6 39
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D5ZHKA] Terminal C signal: Disconnection
40 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D5ZHKA] Terminal C signal: Disconnection SEN00733-04
WA500-6 41
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D5ZHKB] Terminal C signal: Short circuit
42 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D5ZHKB] Terminal C signal: Short circuit SEN00733-04
WA500-6 43
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit
44 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D5ZHKZ] Terminal C signal: Disconnection or short circuit SEN00733-04
WA500-6 45
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D5ZHL6] Terminal C signal: Signal does not match engine
Failure code [D5ZHL6] Terminal C signal: Signal does not match engine
running or stopped state 1
Action code Failure code Terminal C signal: Signal does not match engine running or stopped
Trouble state
E01 D5ZHL6 (Machine monitor system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and alternator terminal R voltage has been checked.)
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) from starting switch terminal C to machine monitor can be checked with
Related
the monitoring function (Code: 40900, D-IN-2).
information
• Method of reproducing failure code: Set the starting switch to START position
46 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [D5ZHL6] Terminal C signal: Signal does not match engine SEN00733-04
WA500-6 47
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [D5ZHL6] Terminal C signal: Signal does not match engine
48 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree SEN00733-04
Action code Failure code Auto grease controller: ON/OFF signals disagree
Trouble
— DA80L4 (Machine monitor system)
Contents of
• Both circuits of auto-greasing sensor inputs A and B are open, or their voltage is 24V simultaneously.
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
• Auto grease does not work.
appears on
• Auto grease lamp goes off.
machine
• The input state (ON/OFF) from the auto grease controller can be checked with the monitoring function
Related (Code: 40900, D-IN-4, D-IN-5).
information • Applicable only to machines equipped with auto grease function (if equipped)
• Method of reproducing failure code: Turn the starting switch ON (auto grease install)
WA500-6 49
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree
50 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DA80L4] Auto grease controller: ON/OFF signals disagree SEN00733-04
WA500-6 51
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DAF3KK] Machine monitor: Low source voltage (input)
Action code Failure code Machine monitor: Low source voltage (input)
Trouble
E03 DAF3KK (Machine monitor system)
Contents of • When the voltage of the SW power supply (power supply for operation) is above 17 V, the voltage of
trouble the constant power supply (power supply for operation) is below 17 V.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The service meter reading is abnormal, the odometer does not advance and failure history data is
appears on
not saved.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
52 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DAF3KK] Machine monitor: Low source voltage (input) SEN00733-04
WA500-6 53
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DAF5KP] Machine monitor: Low output voltage
54 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DAF5KP] Machine monitor: Low output voltage SEN00733-04
WA500-6 55
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DAFRKR] CAN communication with machine monitor: Com-
Action code Failure code CAN communication with machine monitor: Communication error
Failure (Abnormality in target component system)
E03 DAFRKR (Transmission controller system)
• Transmission controller cannot receive information from machine monitor through CAN communi-
Detail of failure
cation.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
• Uses CAN information obtained from machine monitor just before failure occurs.
troller
• If failure disappears, machine becomes normal by itself.
Problem on
• Machine monitor does not display normally.
machine
• Check that power supply circuit of machine monitor is normal.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting switch is
received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication. Accord-
ingly, if CAN communication with machine monitor fails, failure code [DAFRKR] is not displayed on
Related infor- machine monitor and it can be observed only through KOMTRAX system.
mation • When failure code [D**RKR] or [DB9RMC] is also displayed, write down all of displayed codes.
• Failure code [DAFRKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short
circuit in CAN communication line.
• Since each controller and machine monitor are connected directly to the battery, they are supplied
with power even when starting switch is in OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by using mul-
timeter.
56 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DAQ0KK] Transmission controller: Low source voltage SEN00733-04
WA500-6 57
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DAQ0KK] Transmission controller: Low source voltage
58 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DAQ0KK] Transmission controller: Low source voltage SEN00733-04
WA500-6 59
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DAQ0KT] Transmission controller: Abnormality in controller
60 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DAQ2KK] Transmission controller load power supply line: SEN00733-04
Action code Failure code Transmission controller load power supply line: Low source voltage
Trouble (input)
E03 DAQ2KK (Transmission controller system)
• The voltage of the 24 V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power sup-
trouble
ply) above 20 V and solenoid power supply below 18 V
• Turns the centralized warning lamp and alarm buzzer ON.
• Strain itself not to display failure codes that may be false detected due to low 24 V solenoid source
Action of
voltage
controller
• Even if cause of failure disappears, system does not reset itself until directional lever, joystick steer-
ing FNR (directional) switch, or directional selector switch is set to N (Neutral).
Problem that
• Transmission is stuck in Neutral.
appears on
• The fan rotates forward if reversed.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
WA500-6 61
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DAQ2KK] Transmission controller load power supply line:
62 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DAQ2KK] Transmission controller load power supply line: SEN00733-04
WA500-6 63
Troubleshooting by failure code (Display of code), Part 4
SEN00733-04 Failure code [DAQ9KQ] Transmission controller model selection: Dis-
Action code Failure code Transmission controller model selection: Disagreement of model
Trouble selection signals
E03 DAQ9KQ (Machine monitor system)
Contents of
• The transmission controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Does not display failure codes which may be false detected.
Problem that
appears on • If machine travels as it is, transmission may be broken.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
64 WA500-6
Troubleshooting by failure code (Display of code), Part 4
Failure code [DAQ9KQ] Transmission controller model selection: Dis- SEN00733-04
WA500-6 65
SEN00733-04
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
66
SEN00734-03
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 5
Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormal-
ity in target component system) .................................................................................................................. 4
Failure code [DAQRMA] Transmission controller option setting: Malfunction................................................. 9
Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in
target component system) .........................................................................................................................11
Failure code [DB90KK] Work equipment controller: Low source voltage (input) .......................................... 16
Failure code [DB90KT] Work equipment controller: Abnormality in controller .............................................. 19
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...... 20
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range ............ 24
Failure code [DB99KQ] Work equipment controller model selection: Disagreement of model selection signals
.................................................................................................................................................................. 26
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnor-
mality in target component system) .......................................................................................................... 27
Failure code [DB9RMA] Work equipment controller option setting: Malfunction........................................... 28
WA500-6 1
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03
Failure code [DB9RMC] CAN communication with work equipment controller: Defective operation............ 29
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ............................. 30
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................. 32
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time .............................. 34
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time .............................. 36
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time
.................................................................................................................................................................. 38
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long
time ........................................................................................................................................................... 40
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time........................... 42
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time........ 44
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time ........ 46
Failure code [DD1HLD] Load meter display selector switch: Switch is kept pressed for long time .............. 48
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree............................................... 50
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit ................................. 52
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit ............................ 55
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree ................................ 58
2 WA500-6
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03
WA500-6 3
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DAQRKR] CAN communication with transmission controller:
Action code Failure code CAN communication with transmission controller: Communication
Failure error (Abnormality in target component system)
E03 DAQRKR (Machine monitor system)
Contents of • Machine monitor cannot receive information from transmission controller through CAN communica-
trouble tion circuit.
• Uses CAN information obtained from transmission controller just before failure occurs.
Action of con-
• Lights up centralized warning lamp and sounds alarm buzzer.
troller
• If failure disappears, machine becomes normal by itself.
Problem on
• Machine monitor does not display normally.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting switch is
received.
• When failure code [D**RKR] or [DB9RMC], is also displayed, at least CAN communication between
another controller and machine monitor is established. That is, there cannot be short circuit, ground
fault, or hot short circuit in CAN communication line.
• When [DAQRKR] is displayed, but none of failure codes [D**RKR] and [DB9RMC], is displayed,
Related infor-
CAN communication may not be established between any controllers. That is, there may be short
mation
circuit, ground fault, or hot short circuit in CAN communication line.
• Machine monitor detects only this code in CAN communication errors. Accordingly, when this code
is displayed, it does not always indicate that transmission controller has failure.
• Another controller may have failure and disable whole CAN communication.
• Since each controller and machine monitor are connected directly to the battery, they are supplied
with power even when starting switch is in OFF position.
• Since active signal is pulse voltage, it cannot be measured by using multimeter.
4 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DAQRKR] CAN communication with transmission control- SEN00734-03
WA500-6 5
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DAQRKR] CAN communication with transmission controller:
6 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DAQRKR] CAN communication with transmission control- SEN00734-03
WA500-6 7
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DAQRKR] CAN communication with transmission controller:
8 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DAQRMA] Transmission controller option setting: Malfunc- SEN00734-03
WA500-6 9
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DAQRMA] Transmission controller option setting: Malfunc-
10 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB2RKR] CAN communication from engine controller: Com- SEN00734-03
Action code Failure code CAN communication from engine controller: Communication error
Contents of Failure (Abnormality in target component system)
DB2RKR (Transmission controller system)
trouble
Detail of failure 1) Transmission controller cannot recognize engine controller through CAN communication.
• Does not update CAN communication information from engine controller.
• Fixes engine speed to 2,100 rpm.
Action of con- • Fixes throttle position recognition to 80%.
troller • Does not detect slip of modulation clutch.
• Lights up centralized warning lamp and sounds alarm buzzer.
• If failure disappears, machine becomes normal by itself.
Problem on • Information to be obtained from engine controller is not displayed and special functions that need
machine information do not work. In another case, received data are not updated.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting switch is
received.
• When failure code [D**RKR], or [DB9RMC] is also displayed, write down all of displayed codes.
Related infor-
• Failure code [DB2RKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short
mation
circuit in CAN communication line.
• Since each controller and machine monitor are connected directly to the battery, they are supplied
with power even when starting switch is in OFF position.
• Since active signal is pulse voltage, it cannot be measured by using multimeter.
WA500-6 11
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB2RKR] CAN communication from engine controller: Com-
12 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB2RKR] CAN communication from engine controller: Com- SEN00734-03
WA500-6 13
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB2RKR] CAN communication from engine controller: Com-
Contents of
2) Engine controller power supply circuit is defective.
trouble
a See the circuit diagram in contents of trouble 1).
Causes Standard value in normal state/Remarks on troubleshooting
1. Turn starting switch to OFF position.
Defective relays (L117 and 2. Exchange relays (L117 and L119 one by one) for engine
1 L119 for engine controller controller power supply with other relays.
power supply 3. Turn starting switch to ON position.
If this failure code is not displayed, original relay is defective.
1. Turn starting switch to OFF position.
2. Remove diode array D01 and connect T-adapter to male side.
a Measure by using multimeter in diode range.
2 Defective diode D01 Between D01 (male) (1) (+) and (2) (-) Continuity
Between D01 (male) (2) (+) and (1) (-) No continuity
Between D01 (male) (3) (+) and (2) (-) Continuity
Between D01 (male) (2) (+) and (3) (-) No continuity
1. Turn starting switch to OFF position.
2. Remove fuse No.3 in fuse box A. (30 A fuse).
3. Disconnect connectors each of LS4, D01, L117, L119, E18 and
E19, and connect T-adapters to each female side.
Between LS4 (female) (2) and D01 (female) Resis-
Max. 1 z
(1) tance
Between D01 (female) (2) and L117 (female) Resis-
Max. 1 z
(1) tance
Between D01 (female) (2) and L119 (female) Resis-
Max. 1 z
Possible causes (1) tance
and standard Between L117 (female) (2) and L119 Resis-
value in normal Disconnection in wiring har- Max. 1 z
ness (female) (2) tance
state 3
(wire breakage or defective Between L119 (female) (2) and E18 (female) Resis-
Max. 1 z
contact of connector) (33) tance
Between fuse No. 3 of fuse box A and L119 Resis-
Max. 1 z
(female) (5) tance
Between L117 (female) (5) and L119 Resis-
Max. 1 z
(female) (5) tance
Between L117 (female) (3) and E19 (female) Resis-
Max. 1 z
(3) tance
Between L119 (female) (3) and E19 (female) Resis-
Max. 1 z
(4) tance
Between E19 (female) (1), (2) and chassis Resis-
Max. 1 z
ground tance
1. Turn starting switch to OFF position and disconnect ground cable
from battery.
2. Remove fuse No.3 in fuse box A (30 A fuse).
3. Disconnect connectors L117, L119, and E19, and connect T-
adapter to female side.
Ground fault in wiring har-
4 ness Between fuse No.3 of fuse box A, L117 Resis-
Min. 1 Mz
(contact with ground circuit) (female) (5) or L119 (female) (5) and ground tance
Between L117 (female) (3), or E19 (female) Resis-
Min. 1 Mz
(3) and ground tance
Between L119 (female) (3) or E19 (female) Resis-
Min. 1 Mz
(4) and ground tance
14 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB2RKR] CAN communication from engine controller: Com- SEN00734-03
WA500-6 15
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB90KK] Work equipment controller: Low source voltage
Action code Failure code Work equipment controller: Low source voltage (input)
Trouble
E03 DB90KK (Work equipment controller system)
Contents of • Voltage of work equipment controller UNSW power supply (battery direct power supply) is low.
trouble • Voltage of constant power supply (battery direct power supply) is 18 V or less.
• Does not display failure codes other than this code if voltage of constant power supply (battery direct
power supply) remains under 18 V for more than 2 seconds.
Action of • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work
controller equipment lever are set to N (Neutral).
• Turns the centralized warning lamp and alarm buzzer ON.
• Cannot operate normally since it cannot sense the input signals properly.
Problem that
appears on • The machine cannot operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
16 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB90KK] Work equipment controller: Low source voltage SEN00734-03
WA500-6 17
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB90KK] Work equipment controller: Low source voltage
18 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB90KT] Work equipment controller: Abnormality in con- SEN00734-03
WA500-6 19
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB92KK] Work equipment controller load power supply line:
Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input) 1
Action code Failure code Work equipment controller load power supply line: Low source volt-
Trouble age (input)
E03 DB92KK (Work equipment controller system)
• The voltage of the 24V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power sup-
trouble
ply) above 20 V and solenoid power supply below 18 V
• Cannot supply voltage to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.)
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work
equipment lever are set to N (Neutral).
Problem that
appears on • Work equipment does not move.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
20 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB92KK] Work equipment controller load power supply line: SEN00734-03
WA500-6 21
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB92KK] Work equipment controller load power supply line:
22 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB92KK] Work equipment controller load power supply line: SEN00734-03
WA500-6 23
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB95KX] Work equipment controller power supply output:
Action code Failure code Work equipment controller power supply output: Out of input signal
Trouble range
E03 DB95KX (Work equipment controller system)
Contents of
• Normal voltage output of 5 V sensor power supply system is out of range (Outside 4.7 – 5.3 V)
trouble
• Cannot sense the input signals normally due to abnormal potentiometer signal.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The operator cannot operate the work equipment (all stop).
appears on
• The potentiometer errors below occur.
machine
Related • Method of reproducing failure code: Turn starting switch ON.
information • See failure code DH21KA for open circuit in wiring harness.
24 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB95KX] Work equipment controller power supply output: SEN00734-03
WA500-6 25
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB99KQ] Work equipment controller model selection: Dis-
Action code Failure code Work equipment controller model selection: Disagreement of model
Trouble selection signals
E03 DB99KQ (Machine monitor system)
Contents of
• Work equipment controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
controller • Does not display failure codes which may be false detected.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Work equipment may not operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
26 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB9RKR] CAN communication with work equipment con- SEN00734-03
Action code Failure code CAN communication with work equipment controller:
Failure Communication error (Abnormality in target component system)
E03 DB9RKR (Transmission controller system)
• Transmission controller cannot receive CAN communication information from work equipment con-
Detail of failure
troller.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
• Uses CAN information obtained from work equipment controller just before failure occurs.
troller
• If failure disappears, machine becomes normal by itself.
Problem on
machine -
WA500-6 27
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DB9RMA] Work equipment controller option setting: Mal-
Action code Failure code Work equipment controller option setting: Malfunction
Trouble
E03 DB9RMA (Machine monitor system)
Contents of • Optional setting of the machine monitor disagrees with its recognition in the work equipment control-
trouble ler.
Action of • The work equipment controller complies with its optional setting recognition.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Optional components do not operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
28 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DB9RMC] CAN communication with work equipment con- SEN00734-03
Action code Failure code CAN communication with work equipment controller: Defective operation
Trouble
E03 DB9RMC (Work equipment controller system)
• Communication via CAN signal line between the work equipment controller and transmission control-
ler is defective.
Contents of
• The travel speed signal cannot be transmitted from transmission controller.
trouble
• The engine start prohibition signal cannot be transmitted from transmission controller.
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Judges that the travel speed is at 0 km/h.
controller
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Problem that • The operator may not use Semi-automatic digging occasionally or cannot use it entirely.
appears on • The engine can start when the joystick steering lever is not in neutral
machine • Swing speed increases because joystick steering cannot sense travel speed properly.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting switch is
received.
• When failure code [D**RKR] is also displayed, write down all of displayed codes.
Related
• Failure code [DB9RMC] is displayed. That is, there cannot be short circuit, ground fault, or hot short
information
circuit in CAN communication line.
• Since each controller and machine monitor are connected directly to the battery, they are supplied
with power even when starting switch is in OFF position.
• Since active signal is pulse voltage, it cannot be measured by using multimeter.
WA500-6 29
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed
for long time 1
Action code Failure code t Switch (Panel switch 1): Switch is kept pressed for long time
Trouble
E01 DD15LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 1 “t” (Panel switch 1) is kept CLOSED
trouble for more than continuous 1 minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor (cannot enter the service mode).
appears on
• Character display may not display letters.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 1 “t” (Panel switch 1) can
Related be checked with the monitoring function (Code: 40901 D-IN-15).
information • The operator may not be able to use the monitoring function because of the t switch trouble.
• Method of reproducing failure code: Turn starting switch ON.
30 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed
Action code Failure code U Switch (Panel switch 2): Switch is kept pressed for long time
Trouble
E01 DD16LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 2 “U” (Panel switch 2) is kept
trouble CLOSED for more than continuous 1 minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor.
appears on
• Character display may not display letters.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 2 “U” (Panel switch 2)
Related can be checked with the monitoring function (Code: 40901 D-IN-14).
information • The operator may not be able to use the monitoring function because of the U switch trouble.
• Method of reproducing failure code: Turn starting switch ON.
32 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed
for long time 1
Action code Failure code “<” Switch (Panel switch 3): Switch is kept pressed for long time
Trouble
E01 DD17LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 3 “<” (Panel switch 3) is kept CLOSED
trouble for more than continuous 1 minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor.
appears on
• Character display may not display letters.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 3 “<” (Panel switch 3) can
Related be checked with the monitoring function (Code: 40904 D-IN-38).
information • The operator may not be able to use the monitoring function because of the “<” switch trouble.
• Method of reproducing failure code: Turn starting switch ON.
34 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed SEN00734-03
WA500-6 35
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed
for long time 1
Action code Failure code “>” Switch (Panel switch 4): Switch is kept pressed for long time
Trouble
E01 DD18LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 4 “>” (Panel switch 4) is kept CLOSED
trouble for more than continuous 1 minute.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 “>” (Panel switch 4) can
Related be checked with the monitoring function (Code: 40904 D-IN-37).
information • The operator may not be able to use the monitoring function because of the “>” switch trouble.
• Method of reproducing failure code: Turn starting switch ON.
36 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):
Action code Failure code Remote positioner raise/lower set switch (raise): Switch is kept
Trouble pressed for long time
E01 DD1ALD (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (raise) system has a grounding fault, operator
trouble cannot set raising.
• Stops setting the lift arm raise set position.
Action of • Stops the remote raise stop operation.
controller • Turns the lift arm raise set indicator OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The operator cannot set the lift arm raise set position.
appears on
• The remote positioner raise stop control does not operate.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (raise) can be checked
Related
with the monitoring function (Code: 40913 D-IN-28).
information
• Method of reproducing failure code: Turn starting switch ON.
38 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Action code Failure code Remote positioner raise/lower set switch (lower): Switch is kept
Trouble pressed for long time
E01 DD1BLD (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (lower) system has a grounding fault, operator
trouble cannot set lowering.
• Stops setting the lift arm lower set position.
Action of • Stops the remote lower stop operation.
controller • Turns the lift arm lower set indicator OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The operator cannot set the lower set position.
appears on
• The remote positioner lower stop control does not operate.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (lower) can be checked
Related
with the monitoring function (Code: 40913 D-IN-29).
information
• Method of reproducing failure code: Turn starting switch ON.
40 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed
for long time 1
Action code Failure code Load meter subtotal switch: Switch is kept pressed for long time
Trouble
E01 DD1CLD (Machine monitor system)
Contents of • The load meter subtotal switch may not operate because of grounding fault in load meter subtotal
trouble switch system.
Action of
• None in particular.
controller
Problem that
• The total amount of load cannot be set to 0 on the screen.
appears on
• Data cannot be output to printer (if equipped).
machine
• The input state (ON/OFF) from the load meter subtotal switch can be checked with the monitoring
Related function (Code: 40904 D-IN-32)
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.
42 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept SEN00734-03
Circuit diagram related to load meter cancel switch & subtotal switch
WA500-6 43
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is
kept pressed for long time 1
Action code Failure code Load meter mode selector switch (A/B): Switch is kept pressed for
Trouble
E01 DD1FLD long time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (A/B) is kept CLOSED for more than contin-
trouble uous 1 minute
Action of
• None in particular.
controller
Problem that
• The working object cannot be changed.
appears on
• Character display may not display letters.
machine
• The input state (ON/OFF) from the load meter mode selector switch (A/B) can be checked with the
Related monitoring function (Code: 40901 D-IN-10).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.
44 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is
kept pressed for long time 1
Action code Failure code Load meter mode selector switch (+/–): Switch is kept pressed for
Trouble long time
E01 DD1GLD (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (+/–) is kept CLOSED for more than continu-
trouble ous 1 minute
Action of
• None in particular.
controller
Problem that
• The operator cannot make settings of load meter addition mode.
appears on
• Character display may not display letters.
machine
• The input state (ON/OFF) from the load meter mode selector switch (+/–) can be checked with the
Related monitoring function (Code: 40901 D-IN-11).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.
46 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DD1HLD] Load meter display selector switch: Switch is kept
Action code Failure code Load meter display selector switch: Switch is kept pressed for long
Trouble time
E01 DD1HLD (Machine monitor system)
Contents of • The load meter display selector switch does not operate because of grounding fault in the load meter
trouble display selector switch system.
Action of
• None in particular.
controller
Problem that
• Unable to display cumulative data
appears on
• Character display may not display letters.
machine
• The input state (weight) from the load meter display selector switch can be checked with the monitor-
Related ing function (Code: 40902 D-IN-23).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.
48 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DD1HLD] Load meter display selector switch: Switch is kept SEN00734-03
WA500-6 49
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree 1
Action code Failure code RPM set ON/OFF switch: ON/OFF signals disagree
Trouble
E01 DDA7L4 (Transmission controller system)
Contents of
• RPM set does not function because of a hot short circuit in RPM set ON/OFF switch system.
trouble
Action of • Turns RPM set function OFF
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set ON/OFF switch (pressed upward) can be checked with
the monitoring function (Code: 95500 THROT LOCK A).
Related
• The input state (ON/OFF) from the RPM set ON/OFF switch (pressed downward) can be checked
information
with the monitoring function (Code: 95501 THROT LOCK B).
• Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON
50 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up):
Action code Failure code RPM set idle-up/down selector switch (idle-up): Short circuit
Trouble
E01 DDA8KB (Transmission controller system)
Contents of • Idle-up switch is misjudged to be ON due to ground fault in RPM set idle-up/down selector switch
trouble (idle-up) system.
Action of • Turns RPM set function OFF
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-up)
52 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up):
54 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): SEN00734-03
Action code Failure code RPM set idle-up/down selector switch (idle-down): Short circuit
Trouble
E01 DDA9KB (Transmission controller system)
Contents of • Idle-down switch is misjudged to be ON due to ground fault in RPM set idle-up/down switch (idle-
trouble down) system.
Action of • Turns RPM set function OFF
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-down)
WA500-6 55
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down):
56 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): SEN00734-03
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Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals
Action code Failure code Parking brake switch (Neutralizer): ON/OFF signals disagree
Trouble
E03 DDB6L4 (Transmission controller system)
• Controller outputs a failure signal when all the following conditions are satisfied.
Contents of 1) Parking brake switch signal ON (neutralizer signal OPEN)
trouble 2) Parking brake released (by CAN communication from the machine monitor)
3) Hydraulic oil temperature under 25°C
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Forward-reverse cannot be operated, or parking brake indicator lamp remains turned off.
machine
• The input state (ON/OFF) from the parking indicator switch to the machine monitor can be checked
with the monitoring function (Code: 40903 D-IN-26).
• The input state (ON/OFF) from the parking brake switch can be checked with the monitoring function
(Code: 40907 D-IN-23).
• If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) is displayed,
Related
carry out troubleshooting for it first.
information
• If failure code [DAFRKR] (Machine monitor CAN communication: Defective communication (Abnor-
mality in target component system) is displayed, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch and parking brake switch ON
• If emergency parking brake reset switch is turned ON (set to release position) while parking brake
switch is ON (set to parking position), this error may be detected.
58 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF sig- SEN00734-03
WA500-6 59
Troubleshooting by failure code (Display of code), Part 5
SEN00734-03 Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals
60 WA500-6
Troubleshooting by failure code (Display of code), Part 5
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF sig- SEN00734-03
WA500-6 61
SEN00734-03
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
62
SEN00735-01
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 6
Troubleshooting by failure code (Display of code), Part 6 .............................................................................. 4
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) ............................................................................................ 4
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) ............................................ 6
Failure code [DDK3KA] (Right FNR switch: Disconnection) ................................................................ 8
Failure code [DDK3KB] (Right FNR switch: Short circuit) .................................................................. 10
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) ............................................ 12
Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)................................................ 14
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) ............. 16
Failure code [DDK6KA] (FNR lever switch: Disconnection) ............................................................... 18
Failure code [DDK6KB] (FNR lever switch: Short circuit) .................................................................. 22
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) ............................... 24
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) ....... 26
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)............................ 28
WA500-6 1
SEN00735-01 40 Troubleshooting
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) ..................................... 30
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)................ 32
Failure code [DF10KA] (Transmission shift lever switch: Disconnection) .......................................... 34
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) .............................................. 38
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) ................................ 40
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit).................................... 42
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) ..................... 44
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) ................................... 46
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)................... 48
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) .......... 50
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) ....................... 52
2 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 3
SEN00735-01 40 Troubleshooting
Action code Failure code Remote positioner bucket angle set switch: Switch is kept pressed
Trouble for long time
E01 DDD1LD (Work equipment controller system)
• Unable to set the bucket to a specified angle due to ground fault in the remote positioner bucket
Contents of
angle set switch system.
trouble
• Detected continuous operation for 30 seconds and longer.
Action of • Judged that remote positioner bucket angle set switch is turned ON
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Remote positioner raise set signal: Setting is changed to upward by 1° (degree) and the monitor dis-
Problem that plays the changed angle
appears on • Remote positioner lower set signal: Setting is changed to downward by 1° (degree) and the monitor
machine displays the changed angle
• Cannot be changed to upward or downward.
• The input state (ON/OFF) from the remote positioner bucket angle set switch can be checked with
the monitoring function (Code: 40911 D-IN-10, D-IN-11).
Related
• Only for load meter (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and remote positioner bucket angle set
switch ON
4 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 5
SEN00735-01 40 Troubleshooting
6 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 7
SEN00735-01 40 Troubleshooting
8 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 9
SEN00735-01 40 Troubleshooting
10 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 11
SEN00735-01 40 Troubleshooting
12 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 13
SEN00735-01 40 Troubleshooting
Action code Failure code Joystick steering FNR switch: Short circuit
Trouble
E03 DDK4KB (Transmission controller system)
Contents of • Multiple signals are input due to grounding fault in joystick steering FNR (directional) switch input sig-
trouble nal system.
• Sets to neutral
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering FNR (direc-
tional) switch is set to N (Neutral).
Problem that • Machine cannot be moved with FNR switch.
appears on • Machine can be moved with directional lever.
machine • Multiple shift lever position pilot lamps light up.
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional)
switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or Code: 40942
Related D-IN-32).
information • Only for joystick steering (If equipped)
• Method of reproducing failure code: Turn the starting switch and joystick ON/OFF switch ON + Oper-
ate joystick steering FNR (directional) switch.
14 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 15
SEN00735-01 40 Troubleshooting
Action code Failure code Joystick steering shift-up/down switch: ON/OFF signals disagree
Trouble
E01 DDK5L4 (Transmission controller system)
Contents of
• Multiple signals are input due to grounding fault in joystick steering shift-up/down switch system.
trouble
Action of • Turns the joystick steering shift-up/down function OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Shift-up/down cannot be performed by joystick steering.
machine
• The input signal (ON/OFF) from the joystick steering shift-up/down switch can be checked with the
Related monitoring function (Code: 40905 D-IN-1 or D-IN-2).
information • Method of reproducing failure code: Turn the starting switch ON + Joystick ON/OFF switch ON +
Joystick steering shift-up/down switch ON
16 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 17
SEN00735-01 40 Troubleshooting
18 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 19
SEN00735-01 40 Troubleshooting
20 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 21
SEN00735-01 40 Troubleshooting
22 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 23
SEN00735-01 40 Troubleshooting
Action code Failure code Shift mode selector switch: ON/OFF signals disagree
Trouble
E01 DDT0L4 (Transmission controller system)
Contents of
• The signals input from the transmission manual/auto shift selector switch are combined impossibly.
trouble
Action of • Selects the manual shift mode.
controller • If cause of failure disappears, system resets itself.
Problem that
• The position of the transmission manual/auto shift selector switch does not match the shift mode dur-
appears on
ing auto shift.
machine
• The input state (H/L) from the transmission manual/auto shift selector switch can be checked with
Related the monitoring function (Code: 40905 D-IN-4, D-IN-5).
information • The operator can check the current shift mode with the automatic shift pilot lamp.
• Method of reproducing failure code: Turn starting switch ON.
24 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 25
SEN00735-01 40 Troubleshooting
Action code Failure code Transmission cut-off set switch: Switch is kept pressed for long time
Trouble
E01 DDT4LD (Transmission controller system)
Contents of • Transmission cut-off is not performed normally due to grounding fault in transmission cut-off set
trouble switch system.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Transmission cut-off is performed at unintended position.
machine
• The input state (ON/OFF) from the transmission cut-off set switch can be checked with the monitor-
Related
ing function (Code: 40906 D-IN-9).
information
• Method of reproducing failure code: Turn starting switch ON.
26 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 27
SEN00735-01 40 Troubleshooting
Action code Failure code Kick-down switch: Switch is kept pressed for long time
Trouble
E01 DDW9LD (Transmission controller system)
Contents of
• The kick-down does not function due to grounding fault in kick-down switch system.
trouble
Action of • Turns the kick-down ON when a grounding fault is detected, then do not control the kick-down.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When ground fault occurs, kick-down is turned ON once but is not turned ON any more.
machine
• The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
Related
(Code: 40906 D-IN-10).
information
• Method of reproducing failure code: Turn starting switch ON.
28 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 29
SEN00735-01 40 Troubleshooting
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long
time) 1
Action code Failure code Hold switch: Switch is kept pressed for long time
Trouble
E01 DDWLLD (Transmission controller system)
Contents of
• Since the hold switch system is in ground fault, the hold switch does not function.
trouble
Action of • Holds once when a grounding fault occurs, then do not control holding.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When ground fault occurs, turn the hold switch once.
machine
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code:
Related
40906 D-IN-11).
information
• Method of reproducing failure code: Turn starting switch ON.
30 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 31
SEN00735-01 40 Troubleshooting
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed
for long time) 1
Action code Failure code Load meter cancel switch: Switch is kept pressed for long time
Trouble
E01 DDY0LD (Machine monitor system)
Contents of
• The load meter cancel switch is in ground fault and load meter cancel switch does not function.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Unable to cancel calculated load weight.
machine
• The input state (ON/OFF) from the load meter cancel switch can be checked with the monitoring
Related function (Code: 40904 D-IN-33).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn starting switch ON.
32 WA500-6
40 Troubleshooting SEN00735-01
Circuit diagram related to load meter cancel switch & subtotal switch
WA500-6 33
SEN00735-01 40 Troubleshooting
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36 WA500-6
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Action code Failure code Transmission shift lever switch: Short circuit
Trouble
E01 DF10KB (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is in hot short circuit, multiple transmis-
trouble sion shift lever switch signals are input.
Action of • Uses the shift range input to the higher gear speed
controller • If cause of failure disappears, system resets itself.
Problem that • The relevant gear speed is not set. (The transmission does not shift into 1st or 2nd even if the trans-
appears on mission shift lever is used.)
machine • Shift indicator indicates the shift range input to the higher gear speed.
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related
40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever
38 WA500-6
40 Troubleshooting SEN00735-01
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40 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 41
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Action code Failure code Transmission oil temperature sensor: Short circuit
Trouble
E01 DGF1KB (Transmission controller system)
• Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the transmission oil temperature is higher.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Gear shift shock may occur.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
information
itoring function (Code: 93601 T/M OIL TEMP).
• Method of reproducing failure code: Turn starting switch ON.
42 WA500-6
40 Troubleshooting SEN00735-01
WA500-6 43
SEN00735-01 40 Troubleshooting
Action code Failure code Hydraulic oil temperature sensor: Out of input signal range
Trouble
E01 DGH2KX (Machine monitor system)
• Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The hydraulic oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404 HYD TEMP).
• Method of reproducing failure code: Turn starting switch ON.
44 WA500-6
40 Troubleshooting SEN00735-01
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SEN00735-01 40 Troubleshooting
Action code Failure code Rear brake oil temperature sensor: Disconnection
Trouble
E01 DGR2KA (Machine monitor system)
Contents of
• Rear brake oil temperature sensor signal system disconnection.
trouble
Action of • Judges that the rear brake oil temperature is lower
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).
• Method of reproducing failure code: Turn starting switch ON.
46 WA500-6
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WA500-6 47
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Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input
signal range) 1
Action code Failure code Rear brake oil temperature sensor: Out of input signal range
Trouble
E01 DGR2KX (Machine monitor system)
• Due to grounding fault in rear brake oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).
• Method of reproducing failure code: Turn starting switch ON.
48 WA500-6
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Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of • Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
trouble than normal range (Transmission oil temperature voltage: Max. 0.97 V (Min. 150°C))
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The torque converter oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).
• Method of reproducing failure code: Turn starting switch ON.
50 WA500-6
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WA500-6 51
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Action code Failure code Work equipment pump oil pressure sensor: Disconnection
Trouble
E01 DH21KA (Work equipment controller system)
• Due to disconnection or grounding fault in the work equipment oil pressure sensor system, the signal
Contents of
voltage is lower than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Max. 0.3 V)
Action of • Judges that work equipment pump oil pressure reads 0
controller • If cause of failure disappears, system resets itself.
Problem that
• Remote positioner inaccuracy of stopping
appears on
• When work equipment is relieved, cut-off does not function
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt
52 WA500-6
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WA500-6 53
SEN00735-01
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 08-06 (01)
54
SEN00736-01
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 7
Troubleshooting by failure code (Display of code), Part 7 .............................................................................. 4
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)............................. 4
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)........... 6
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).............. 8
Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) ............................... 10
Failure code [DHT2L6] (Transmission filter clogging sensor:
Signal disagrees with operating and stopped states of engine).................................................. 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ........................... 14
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line)............................................................................................ 18
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)............. 21
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) ............................ 24
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Short circuit with power supply line)............................................................................................ 27
WA500-6 1
SEN00736-01 40 Troubleshooting
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ............................ 30
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):
Short circuit with power supply line)............................................................................................ 33
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) ............. 36
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) ............................. 39
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Short circuit with power supply line)............................................................................................ 42
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main):
Disconnection) ............................................................................................................................ 45
Failure code [DK5DKY] (3rd valve (attachment) EPC lever potentiometer (Main):
Short circuit with power supply line)............................................................................................ 47
Failure code [DK5DL8] (3rd valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree)............................................................................................................. 49
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection) ............................................................................................................................ 52
2 WA500-6
40 Troubleshooting SEN00736-01
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Action code Failure code Work equipment pump oil pressure sensor: Short circuit
Trouble
E01 DH21KB (Work equipment controller system)
• Due to hot short circuit in the work equipment pump oil pressure sensor signal system, the signal
Contents of
voltage is higher than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges that work equipment pump oil pressure is higher
controller • If cause of failure disappears, system resets itself.
Problem that
• Remote positioner inaccuracy of stopping
appears on
• When work equipment is relieved, cut-off does not function
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt
Defective work equipment a Prepare with starting switch OFF, then start engine, tilt the bucket
1 pump oil pressure sensor and carry out troubleshooting.
(Internal short circuit) F16 Bucket Voltage
Between (B) and (A) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (C) and (A)
When bucket tilt
Possible causes 3.02 – 3.42 V
relieved
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (2) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) F16 (female) (C) and chassis ground
Wiring harness between L05 (female) (22) –
Voltage Max. 1 V
F16 (female) (B) and chassis ground
a Prepare with starting switch OFF, then start engine, tilt the bucket
and carry out troubleshooting.
L05 Bucket Voltage
Between
Defective work equipment Constant 4.85 – 5.15 V
3 (22) and (21)
controller
Constant 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (2) and (21)
When bucket tilt
3.02 – 3.42 V
relieved
4 WA500-6
40 Troubleshooting SEN00736-01
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Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of
input signal range) 1
Action code Failure code Lift arm cylinder bottom pressure sensor: Out of input signal range
Trouble
E01 DHPCKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder bottom pressure sensor signal, the lift
arm cylinder bottom pressure sensor voltage is lower than normal range
Contents of (Lift arm cylinder bottom pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bot-
tom pressure sensor voltage is higher than normal range
(Lift arm cylinder bottom pressure sensor signal voltage: Min. 4.7 V)
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder bottom pressure sensor can be checked with
the monitoring function (Code: 40400 BOOM BTM PRESS).
Related • The input state (voltage) from the lift arm cylinder bottom pressure sensor can be checked with the
information monitoring function (Code: 40402 BOOM BTM PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation
6 WA500-6
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Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of
input signal range) 1
Action code Failure code Lift arm cylinder bottom head pressure sensor: Out of input signal
Trouble range
E01 DHPDKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder head pressure sensor signal, the lift
arm cylinder head pressure sensor voltage is lower than normal range
Contents of (Lift arm cylinder head pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head
pressure sensor voltage is higher than normal range (Lift arm cylinder head pressure sensor signal
voltage: Min. 4.7 V)
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the
monitoring function (Code: 40500 BOOM HEAD PRESS).
Related • The input state (voltage) from the lift arm cylinder head pressure sensor can be checked with the
information monitoring function (Code: 40501 BOOM HEAD PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation
8 WA500-6
40 Troubleshooting SEN00736-01
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Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal
range) 1
Action code Failure code Left brake pressure sensor: Out of input signal range
Trouble
E01 DHT1KX (Transmission controller system)
Contents of • Due to grounding fault in left brake pressure sensor signal system, the signal level is lower than nor-
trouble mal range
• Turns the transmission cut-off function OFF.
• Disables the change of transmission cut-off setting.
Action of
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
controller
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral); or the
transmission cut-off switch is turned OFF.
Problem that
appears on • The transmission cut-off indicator goes off.
machine
• Left brake pressure sensor input voltage: Max. 0.3 V
• The input state (oil pressure) from the left brake pressure sensor can be checked with the monitoring
Related function (Code: 41201 T/M CUT OFF P).
information • The input state (voltage) from the left brake pressure sensor can be checked with the monitoring
function (Code: 41202 T/M CUT OFF P).
• Method of reproducing failure code: Turn the starting switch and transmission cut-off switch ON.
10 WA500-6
40 Troubleshooting SEN00736-01
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Action code Failure code Transmission filter clogging sensor: Signal disagrees with operating
Trouble
E01 DHT2L6 and stopped states of engine (Machine monitor system)
• Due to disconnection or hot short circuit in transmission filter clogging sensor signal, transmission fil-
Contents of
ter clogging sensor signal voltage does not agree with the engine operation or stopping in normal
trouble
condition.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The transmission filter clogging caution lamp does not light up.
machine
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the mon-
Related
itoring function (Code: 40903 D-IN-24).
information
• Method of reproducing failure code: Start engine and drive the machine in high idle
12 WA500-6
40 Troubleshooting SEN00736-01
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Action code Failure code Lift arm EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer system, the signal
Contents of
voltage is lower than normal range
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever
14 WA500-6
40 Troubleshooting SEN00736-01
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16 WA500-6
40 Troubleshooting SEN00736-01
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Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short
circuit with power supply line) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Short circuit with power
Trouble supply line
E03 DK59KY (Work equipment controller system)
• Due to hot short circuit in the lift arm EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever
18 WA500-6
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WA500-6 19
SEN00736-01 40 Troubleshooting
20 WA500-6
40 Troubleshooting SEN00736-01
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog
signals disagree) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)
• Lift arm EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or
trouble
(Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Min. 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±
5%, as the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
Action of
trality ± 5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, lift arm does not move.
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever
WA500-6 21
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22 WA500-6
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Action code Failure code Lift arm EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Sub) system, the sig-
Contents of
nal voltage is lower than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Max.
trouble
0.3 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever
24 WA500-6
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SEN00736-01 40 Troubleshooting
26 WA500-6
40 Troubleshooting SEN00736-01
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short
circuit with power supply line) 1
Action code Failure code Lift arm EPC lever potentiometer (Sub): Short circuit with power
Trouble supply line
E03 DK5AKY (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is
trouble higher than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever
WA500-6 27
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28 WA500-6
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Action code Failure code Bucket EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Main) system, the
Contents of
signal voltage is lower than normal range
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever
30 WA500-6
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WA500-6 31
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32 WA500-6
40 Troubleshooting SEN00736-01
Action code Failure code Bucket EPC lever potentiometer (Main): Short circuit with power
Trouble supply line
E03 DK5BKY (Work equipment controller system)
• Due to hot short circuit in the bucket EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever
Possible causes (Internal short circuit) S02 Bucket EPC lever Voltage
and standard Between (4) and (1) Constant 4.85 – 5.15 V
value in normal Lever in neutral 2.40 – 2.60 V
state
Tilt operation
3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short in wiring harness Wiring harness between L05 (female) (7) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S02 (female) (3) and chassis ground
Between L05 (female) (22) – S02 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
WA500-6 33
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34 WA500-6
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Action code Failure code Bucket EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK5BL8 (Work equipment controller system)
• Bucket EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Bucket EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or (Bucket EPC
trouble
lever potentiometer signal voltage (Total of Main and Sub): Min 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality
±5%, as the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
Action of
trality ±5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, bucket does not move.
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever
36 WA500-6
40 Troubleshooting SEN00736-01
WA500-6 37
SEN00736-01 40 Troubleshooting
38 WA500-6
40 Troubleshooting SEN00736-01
Action code Failure code Bucket EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal volt-
trouble
age: Max. 0.3 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever
WA500-6 39
SEN00736-01 40 Troubleshooting
40 WA500-6
40 Troubleshooting SEN00736-01
WA500-6 41
SEN00736-01 40 Troubleshooting
Action code Failure code Bucket EPC lever potentiometer (Sub): Short circuit with power supply
Trouble line
E03 DK5CKY (Work equipment controller system)
• Due to hot short circuit in the bucket EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal volt-
trouble
age: Min. 4.7 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever
42 WA500-6
40 Troubleshooting SEN00736-01
WA500-6 43
SEN00736-01 40 Troubleshooting
44 WA500-6
40 Troubleshooting SEN00736-01
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Discon-
Trouble nection
E03 DK5DKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Main), the signal voltage is lower than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional
setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
WA500-6 45
SEN00736-01 40 Troubleshooting
46 WA500-6
40 Troubleshooting SEN00736-01
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Short
Trouble circuit with power supply line
E03 DK5DKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Main) system the
Contents of
signal voltage is higher than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 4.7 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional
setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
WA500-6 47
SEN00736-01 40 Troubleshooting
48 WA500-6
40 Troubleshooting SEN00736-01
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Analog
Trouble signals disagree
E03 DK5DL8 (Work equipment controller system)
• The 3-spool valve (attachment) EPC lever potentiometer (Main and Sub) input signals disagree with
Contents of each other. (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of Main and
trouble Sub): Max. 4.7 V) or (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of
Main and Sub): Min. 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±
5%, as the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
Action of
trality ± 5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
Problem that
neutral.
appears on
• If both Main and Sub potentiometers are abnormal, 3-spool valve (attachment) cylinder does not
machine
move.
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional
setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
WA500-6 49
SEN00736-01 40 Troubleshooting
50 WA500-6
40 Troubleshooting SEN00736-01
WA500-6 51
SEN00736-01 40 Troubleshooting
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Discon-
Trouble nection
E03 DK5EKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Sub), the signal voltage is lower than normal range (3-spool valve (attachment) EPC lever potenti-
trouble
ometer (Sub) signal voltage: Max. 0.3 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
Action of is in control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed.
(If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on
the optional setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
52 WA500-6
40 Troubleshooting SEN00736-01
WA500-6 53
SEN00736-01
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 08-06 (01)
54
SEN00737-01
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 8
Troubleshooting by failure code (Display of code), Part 8 .............................................................................. 4
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):
Short circuit with power supply line).............................................................................................. 4
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) .............. 6
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line).............................................................................................. 8
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) ............. 10
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Short circuit with power supply line)............................................................................................ 12
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree)............................................................................................................. 14
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)......................................................... 18
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) ........................................ 20
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) ........................ 22
WA500-6 1
SEN00737-01 40 Troubleshooting
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ...................................................... 24
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection).............................. 26
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree) ............... 28
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit) ............................... 30
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range) ........... 32
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) ....................................... 34
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) .......................... 36
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) ......................... 38
Failure code [DV00KB] (Alarm buzzer: Short circuit) ......................................................................... 40
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) .............................................. 42
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) ................................................. 43
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ............. 44
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)............................................. 46
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ................................................ 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ............ 48
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)................................................... 50
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) ...................................................... 52
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) .................. 54
2 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 3
SEN00737-01 40 Troubleshooting
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Short
Trouble circuit with power supply line
E03 DK5EKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Sub) system, the
Contents of
signal voltage is higher than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional
setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
checked with the monitoring function (Code: 42007 3RD POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
4 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 5
SEN00737-01 40 Troubleshooting
Action code Failure code Joystick steering EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5FKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system
Contents of
(main), the signal voltage is lower than normal range.
trouble
(Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is
set to N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joystick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever
6 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 7
SEN00737-01 40 Troubleshooting
Action code Failure code Joystick steering EPC lever potentiometer (Main): Short circuit with
Trouble the power supply line
E03 DK5FKY (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Main) system, the signal
Contents of
voltage is higher than normal range
trouble
(Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 4.7 V).
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is
set to N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever
8 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 9
SEN00737-01 40 Troubleshooting
Action code Failure code Joystick steering EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5GKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system
Contents of
(Sub), the signal voltage is lower than normal range
trouble
(Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V).
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever
10 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 11
SEN00737-01 40 Troubleshooting
Action code Failure code Joystick steering EPC lever potentiometer (Sub): Short circuit with
Trouble the power supply line
E03 DK5GKY (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Sub) system, the signal volt-
Contents of
age is higher than normal range
trouble
(Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 4.7 V).
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is
set to N (Neutral).
Problem that
appears on —
machine
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever
12 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 13
SEN00737-01 40 Troubleshooting
Action code Failure code Joystick steering EPC lever potentiometer (Main): Analog signals
Trouble
E03 DK5FL8 disagree (Work equipment controller system)
• Joystick steering EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Joystick steering EPC lever potentiometer signal voltage (both Main and Sub): Max. 4.7 V) or (Joy-
trouble
stick steering EPC lever potentiometer signal voltage (both Main and Sub): Min 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±
5%, as the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
Action of
trality ± 5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is
set to N (Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the joystick steer-
appears on ing EPC lever is set to neutral.
machine • If both Main and Sub potentiometers are abnormal, steering cylinder does not move.
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.
14 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 15
SEN00737-01 40 Troubleshooting
16 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 17
SEN00737-01 40 Troubleshooting
18 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 19
SEN00737-01 40 Troubleshooting
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) 1
Action code Failure code Lift arm angle sensor: Out of input signal range
Trouble
E01 DKA0KX (Machine monitor system)
• Due to grounding fault in lift arm angle sensor system, the signal voltage is not input (Lift arm angle
Contents of sensor signal voltage: Max. 1 V).
trouble • Due to disconnection or hot short circuit in lift arm angle sensor system, the signal voltage is higher
than normal level (Lift arm angle sensor signal voltage: Min. 4 V).
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06001 BOOM ANG).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
(Code: 06003 BOOM ANG).
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshoot-
ing for it first.
• Method of reproducing failure code: Turn starting switch ON.
20 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 21
SEN00737-01 40 Troubleshooting
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power
supply line) 1
Action code Failure code Lift arm angle sensor: Short circuit with power supply line
Trouble
E01 DKA0KY (Work equipment controller system)
Contents of • Due to hot short in lift arm angle sensor system, the signal voltage is higher than normal range
trouble (Lift arm angle sensor signal: Min. 4.7 V).
• Judges that lift arm is at the highest position.
• Resets the remote positioner function.
• Resets semi auto digging function.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
remote positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF
• Even if cause of failure disappears, system does not reset itself until lift arm lever is set to N (Neutral).
Problem that • Remote positioner malfunction
appears on • Faulty semi-auto digging operation
machine • No PC control while the lift arm is rising
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002 BOOM ANG).
Related
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
information
(Code: 06005 BOOM ANG).
• Method of reproducing failure code: Turn starting switch ON.
22 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 23
SEN00737-01 40 Troubleshooting
Action code Failure code Lift arm angle sensor: Double meshing
Trouble
E01 DKA0L0 (Work equipment controller system)
Contents of • Due to lift arm angle sensor dislocation, lift arm angle is not detectable correctly.
trouble (Lift arm angle upper limit + 5° and above or lift arm angle lower limit + 5° or above)
• Resets the remote positioner function.
• Resets semi auto digging function.
• No PC control while the lift arm is rising.
Action of
• When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
controller
remote positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF
• If cause of failure disappears, system resets itself.
Problem that • Remote positioner malfunction (Not stop)
appears on • Faulty semi-auto digging operation (Not operate)
machine • No PC control while the lift arm is rising
• This failure code may be displayed when the initial setting of the lift arm angle sensor failed.
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
Related (Code: 06002 BOOM ANG).
information • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06005 BOOM ANG).
• Method of reproducing failure code: Start engine and set the lift arm to raise or lower stroke end
24 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 25
SEN00737-01 40 Troubleshooting
Action code Failure code Transmission input shaft speed sensor: Disconnection
Trouble
E01 DLF1KA (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission input shaft speed sensor system, the sig-
Contents of nal voltage is higher than normal range
trouble (Transmission input shaft speed sensor signal: Min. 1.5 V)
• Signal from the transmission input shaft speed sensor: 0 rpm
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on —
machine
• The input state (speed) from the transmission input shaft speed sensor can be checked with the
Related
monitoring function (Code: 31200 T/M SPEED IN).
information
• Method of reproducing failure code: Start engine and drive the machine
26 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 27
SEN00737-01 40 Troubleshooting
Action code Failure code Transmission input shaft speed sensor: Speed signals disagree
Trouble
E01 DLF1LC (Transmission controller system)
• Due to grounding fault in the transmission input shaft speed sensor, the transmission input shaft
speed sensor signal voltage is lower than normal range.
• This failure code appears under the following conditions. ([A] or [B])
[A]
1) Transmission output shaft speed sensor and transmission input shaft speed obtained from
reduction ratio: Min. 200 rpm
Contents of
2) Signal from transmission input shaft speed sensor: 0 rpm
trouble
3) Transmission input shaft speed sensor signal line: Disconnection is not detected.
[B]
1) Difference between actual transmission output shaft speed and output shaft speed obtained
from input shaft speed sensor and reduction ratio is larger than 200 rpm.
2) Output shaft speed is sensed.
3) Input shaft speed is sensed.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on —
machine
• The input state (speed) from the transmission input shaft speed sensor can be checked with the
Related monitoring function (Code: 31200, T/M SPEED IN).
information • Method of reproducing failure code: Start engine and drive the machine
• This error may be detected when engine stalls.
28 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 29
SEN00737-01 40 Troubleshooting
Action code Failure code Transmission output shaft speed sensor: Short circuit
Trouble
E03 DLT4KB (Transmission controller system)
• Due to grounding fault in the transmission output shaft speed sensor system, transmission output
shaft speed sensor signal voltage is lower than normal range.
• This failure code appears under the following conditions. ([A] or [B])
[A]
1) Transmission input shaft speed sensor and transmission output shaft speed obtained from
reduction ratio: Min. 200 rpm
Contents of
2) Transmission output shaft speed sensor: 0 rpm
trouble
3) Transmission output shaft speed sensor signal line: Disconnection is not detected.
[B]
1) Difference between actual transmission output shaft speed and output shaft speed obtained
from input shaft speed sensor and reduction ratio is larger than 200 rpm.
2) Output shaft speed is sensed.
3) Input shaft speed is sensed.
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
Action of • In the manual-shift mode, performs the normal control.
controller • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control
operation.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Does not change to auto shift mode (changes to manual shift mode).
Problem that
• No travel speed limit function
appears on
• No transmission protection function
machine
• Gear shifting shocks are made.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related monitoring function (Code: 31400, T/M SPEED OUT).
information • Method of reproducing failure code: Start engine and drive the machine
• This error may be detected when engine stalls.
30 WA500-6
40 Troubleshooting SEN00737-01
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SEN00737-01 40 Troubleshooting
Action code Failure code Transmission output shaft speed sensor: Out of input signal range
Trouble
E03 DLT4KX (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission output shaft speed sensor system, the
Contents of signal voltage is higher than normal range
trouble (Transmission output shaft speed sensor signal: Min. 1.5 V).
• Signal from the transmission output shaft speed sensor: 0 rpm
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
Action of • In the manual-shift mode, performs the normal control.
controller • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control
operation.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Does not change to auto shift mode (changes to manual shift mode).
Problem that
• No travel speed limit function
appears on
• No transmission protection function
machine
• Gear shifting shocks are made.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related
monitoring function (Code: 31400, T/M SPEED OUT).
information
• Method of reproducing failure code: Start engine and drive the machine
32 WA500-6
40 Troubleshooting SEN00737-01
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Action code Failure code Transmission cut-off indicator lamp: Short circuit
Trouble
E01 DT20KB (Transmission controller system)
Contents of • Due to grounding fault in transmission cut-off indicator lamp system, the signal is not output to the
trouble indicator lamp.
Action of • Turns the transmission cut-off indicator lamp output OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cut-off indicator lamp does not light up.
machine
Related
• Method of reproducing failure code: Start engine and turn the transmission cut-off switch ON.
information
34 WA500-6
40 Troubleshooting SEN00737-01
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SEN00737-01 40 Troubleshooting
Action code Failure code Remote positioner raise set indicator lamp: Short circuit
Trouble
— DUM1KB (Work equipment controller system)
Contents of • Since the remote positioner raise set indicator lamp system is shorted with the chassis ground, the
trouble signal is not output to the indicator lamp.
Action of • Turns off the remote positioner raise set indicator output.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The remote positioner raise set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner raise set indicator lamp can be checked with the
Related
monitoring function (Code: 40954 D-OUT-18).
information
• Method of reproducing failure code: Start engine.
36 WA500-6
40 Troubleshooting SEN00737-01
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SEN00737-01 40 Troubleshooting
Action code Failure code Remote positioner lower set indicator lamp: Short circuit
Trouble
— DUM2KB (Work equipment controller system)
Contents of • Since the remote positioner lower set indicator lamp system is shorted with the chassis ground, the
trouble signal is not output to the indicator lamp.
Action of • Turns off the remote positioner lower set indicator output.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The remote positioner lower set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner lower set indicator lamp can be checked with the
Related
monitoring function (Code: 40954 D-OUT-19).
information
• Method of reproducing failure code: Start engine.
38 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 39
SEN00737-01 40 Troubleshooting
40 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 41
SEN00737-01 40 Troubleshooting
Action code Failure code Lift arm raise EPC solenoid: Disconnection
Trouble
E03 DW4PKA (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm raise EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not rise
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
Related
(Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise
42 WA500-6
40 Troubleshooting SEN00737-01
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1
Action code Failure code Lift arm raise EPC solenoid: Short circuit
Trouble
E03 DW4PKB (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm raise EPC solenoid output was ON.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of • Stops outputting the signal to the lift arm raise detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not rise
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
Related
(Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise
WA500-6 43
SEN00737-01 40 Troubleshooting
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Lift arm raise EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4PKY (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm raise EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The lift arm raise EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.
44 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 45
SEN00737-01 40 Troubleshooting
Action code Failure code Lift arm lower EPC solenoid: Disconnection
Trouble
E03 DW4QKA (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm lower EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not lower.
machine
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
Related
function (Code: 41901 LOWER EPC DIR).
information
• Method of reproducing failure code: Start engine and lower the lift arm.
46 WA500-6
40 Troubleshooting SEN00737-01
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1
Action code Failure code Lift arm lower EPC solenoid: Short circuit
Trouble
E03 DW4QKB (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm lower EPC solenoid output was ON.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of • Stops outputting the signal to the lift arm float detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not lower.
machine
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
Related
function (Code: 41901 LOWER EPC DIR).
information
• Method of reproducing failure code: Start engine and lower the lift arm.
WA500-6 47
SEN00737-01 40 Troubleshooting
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Lift arm lower EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4QKY (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm lower EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The lift arm lower EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.
48 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 49
SEN00737-01 40 Troubleshooting
50 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 51
SEN00737-01 40 Troubleshooting
Action code Failure code Bucket tilt EPC solenoid: Short circuit
Trouble
E03 DW4RKB (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the chassis ground, abnormal cur-
trouble rent flowed when the bucket tilt EPC solenoid output was ON.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of • Stops outputting the signal to the bucket tilt detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Bucket does not tilt.
machine
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
Related
(Code: 41902 TILT EPC DIR).
information
• Method of reproducing failure code: Start engine and tilt the bucket.
52 WA500-6
40 Troubleshooting SEN00737-01
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Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Bucket tilt EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4RKY (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the power source, abnormal volt-
trouble age was applied when the bucket tilt EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The bucket tilt EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.
54 WA500-6
40 Troubleshooting SEN00737-01
WA500-6 55
SEN00737-01
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 08-06 (01)
56
SEN00738-01
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 9
Troubleshooting by failure code (Display of code), Part 9 .............................................................................. 3
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) ............................................... 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) ................................................... 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) ............... 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).......................................................... 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) ........................................................... 10
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) ....................... 12
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) ................................. 14
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) .................................... 14
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) 15
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)............................. 16
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ................................ 18
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
Short circuit with power supply line)............................................................................................ 20
WA500-6 1
SEN00738-01 40 Troubleshooting
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) .............................. 22
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).................................. 24
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Short circuit with power supply line)............................................................................................ 26
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) ............................... 28
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)................................... 30
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Short circuit with power supply line)............................................................................................ 32
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) ................................... 34
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)....................................... 36
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) ......... 38
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).................................................... 40
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) ....................................................... 41
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) ................... 42
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) .................................................... 43
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)........................................................ 44
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)..................................................... 45
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) ........................................................ 46
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) .................... 48
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ................................................. 50
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..................................................... 52
2 WA500-6
40 Troubleshooting SEN00738-01
WA500-6 3
SEN00738-01 40 Troubleshooting
Action code Failure code Bucket dump EPC solenoid: Short circuit
Trouble
E03 DW4SKB (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the bucket dump EPC solenoid output was ON.
• Stops outputting the signal to the bucket dump EPC solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Bucket does not dump.
appears on
• The wiring harness or controller may be burnt out.
machine
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
Related
function (Code: 41903 DUMP EPC DIR).
information
• Method of reproducing failure code: Start engine and dump the bucket.
4 WA500-6
40 Troubleshooting SEN00738-01
WA500-6 5
SEN00738-01 40 Troubleshooting
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Bucket dump EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4SKY (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the bucket dump EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The bucket dump EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
(Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.
6 WA500-6
40 Troubleshooting SEN00738-01
WA500-6 7
SEN00738-01 40 Troubleshooting
8 WA500-6
40 Troubleshooting SEN00738-01
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SEN00738-01 40 Troubleshooting
10 WA500-6
40 Troubleshooting SEN00738-01
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Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power
supply line) 1
Action code Failure code Fan reverse solenoid: Short circuit with power supply line
Trouble
E01 DW7BKY (Transmission controller system)
Contents of • Since the fan reverse solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan reverse switch output was OFF.
Action of • Disables the automatic fan reverse function (if equipped).
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (if
Problem that
equipped) specification.
appears on
• The fan does not rotate normally.
machine
• The machine may overheat.
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information
• Method of reproducing failure code: Turn starting switch ON.
12 WA500-6
40 Troubleshooting SEN00738-01
WA500-6 13
SEN00738-01 40 Troubleshooting
Action code Failure code Hydraulic drive fan neutral solenoid: Disconnection
Trouble
E01 DW7DKA (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in WA500-6.
information
Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit
Trouble
E01 DW7DKB (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in WA500-6.
information
14 WA500-6
40 Troubleshooting SEN00738-01
Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit with power supply
Trouble line
E01 DW7DKY (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in WA500-6.
information
WA500-6 15
SEN00738-01 40 Troubleshooting
Action code Failure code Work equipment neutral lock solenoid: Disconnection
Trouble
E01 DWM1KA (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is disconnected, no current flows when the
trouble work equipment neutral lock solenoid output is ON.
• Stops outputting the signal to each work equipment solenoid according to an input signal from the
Action of
work equipment lock lever.
controller
• If cause of failure disappears, system resets itself.
Problem that
• Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on
ment lock lever.
machine
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position
16 WA500-6
40 Troubleshooting SEN00738-01
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SEN00738-01 40 Troubleshooting
Action code Failure code Work equipment neutral lock solenoid: Short circuit
Trouble
E01 DWM1KB (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is shorted with the chassis ground, no cur-
trouble rent flows when the work equipment neutral lock solenoid output is ON.
• Turns the output to the work equipment neutral lock solenoid ON.
Action of • Stops outputting the signal to each work equipment solenoid according to an input signal from the
controller work equipment lock lever.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on ment lock lever.
machine • The wiring harness or controller may be burnt out.
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position
18 WA500-6
40 Troubleshooting SEN00738-01
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SEN00738-01 40 Troubleshooting
Action code Failure code Work equipment neutral lock solenoid: Short circuit with power sup-
Trouble ply line
E01 DWM1KY (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system was shorted with the power source, abnor-
trouble mal voltage was applied when the work equipment neutral lock solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
Action of • Stops outputting the signal to each work equipment solenoid according to an input signal from the
controller work equipment lock lever.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • All work equipment do not move.
machine
• The work equipment can be operated by disconnecting the connector of the work equipment neutral
lock solenoid.
Related
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
information
monitoring function (Code: 40952, D-OUT-0).
• Method of reproducing failure code: Turn starting switch ON.
20 WA500-6
40 Troubleshooting SEN00738-01
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SEN00738-01 40 Troubleshooting
Action code Failure code Lift arm raise magnet detent solenoid: Disconnection
Trouble
E01 DWN6KA (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm raise magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner raise does not function.
appears on
• The lift arm is not held at the lift arm raise detent position.
machine
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent
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Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit
Trouble
E01 DWN6KB (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The lift arm remote positioner raise does not function.
appears on
• The lift arm is not held at the lift arm raise detent position.
machine
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent
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Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short
circuit with power supply line) 1
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit with power sup-
Trouble ply line
E01 DWN6KY (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• If you perform lift arm raise detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Start engine.
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Action code Failure code Lift arm float magnet detent solenoid: Disconnection
Trouble
E01 DWN7KA (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm float magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner lower does not function.
appears on
• The lift arm is not held at the lift arm float detent position.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.
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Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm float magnet detent solenoid: Short circuit
Trouble
E01 DWN7KB (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm float magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The lift arm remote positioner lower does not function.
appears on
• The lift arm is not held at the lift arm float detent position.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.
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Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short
circuit with power supply line) 1
Action code Failure code Lift arm float magnet detent solenoid: Short circuit with power sup-
Trouble ply line
E01 DWN7KY (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the lift arm float magnet detent solenoid output was OFF.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp to stop lower stop control.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• If you perform lift arm float detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine.
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Action code Failure code Bucket tilt magnet detent solenoid: Disconnection
Trouble
E01 DWN8KA (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system is disconnected, no current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Keeps normal output condition to the bucket tilt magnet detent solenoid.
controller • If cause of failure disappears, system resets itself.
Problem that
• Bucket leveler does not work.
appears on
• The bucket is not held at the bucket tilt detent position.
machine
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent
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Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1
Action code Failure code Bucket tilt magnet detent solenoid: Short circuit
Trouble
E01 DWN8KB (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the bucket tilt magnet detent solenoid output was ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Bucket leveler does not work.
appears on
• The bucket is not held at the bucket tilt detent position.
machine
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent
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Action code Failure code Bucket tilt magnet detent solenoid: Short circuit with power supply
Trouble line
E01 DWN8KY (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the power
trouble source, abnormal voltage was applied when the bucket tilt magnet detent solenoid output was OFF.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
controller • If cause of failure disappears, system resets itself.
• If you perform bucket tilt detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform bucket detent operation, return of the bucket lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Start engine.
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40 WA500-6
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Action code Failure code Fan pump EPC solenoid: Short circuit
Trouble
E01 DX16KB (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when the fan pump EPC solenoid output was ON.
Action of • Turns the output to the fan pump EPC solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
WA500-6 41
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Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Fan pump EPC solenoid: Short circuit with power supply line
Trouble
E01 DX16KY (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan pump EPC solenoid output was OFF.
Action of • Turns the output to the fan pump EPC solenoid OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The fan speed is set to the minimum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
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46 WA500-6
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Action code Failure code Lockup ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH1KY (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the lockup ECMV solenoid output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the FNR (directional) lever, joystick steering
Action of FNR (directional) switch, or right FNR (directional) switch to N (neutral).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
• Neutral is held until the FNR (directional) lever, joystick steering FNR (directional) switch, or right
Problem that
FNR (directional) switch is set to N (neutral).
appears on
• The lockup clutch is always in the meshed state.
machine
• When fault occurs, shock and sound may be made by sudden engagement and engine may stall.
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
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50 WA500-6
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Action code Failure code 1st clutch ECMV solenoid: Short circuit
Trouble
E03 DXH4KB (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 1st clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st),
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
(Code: 31602, ECMV 1 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 1st using the shift down switch or move the
gear shift lever to 1st.
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WA500-6 53
SEN00738-01
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 08-06 (01)
54
SEN00739-01
WA500-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 10
Troubleshooting by failure code (Display of code), Part 10 ............................................................................ 4
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) .................. 4
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) .................................................. 6
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ..................................................... 8
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) ............... 10
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)................................................. 12
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) .................................................... 14
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ................ 16
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) ................................................... 18
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ....................................................... 20
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)................... 22
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection).................................................... 24
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) ....................................................... 26
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) ................... 28
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2 WA500-6
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Action code Failure code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH4KY (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 1st clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31602 ECMV 1 DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
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6 WA500-6
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Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Trouble
E03 DXH5KB (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 2nd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31603 ECMV 2 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 2nd using the shift down switch or move the
gear shift lever to 2nd.
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40 Troubleshooting SEN00739-01
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Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with
power supply line) 1
Action code Failure code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH5KY (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 2nd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31603 ECMV 2 DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
10 WA500-6
40 Troubleshooting SEN00739-01
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SEN00739-01 40 Troubleshooting
12 WA500-6
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Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Trouble
E03 DXH6KB (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 3rd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31604 ECMV 3 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 3rd using the shift down switch or move the
gear shift lever to 3rd.
14 WA500-6
40 Troubleshooting SEN00739-01
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Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with
power supply line) 1
Action code Failure code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH6KY (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 3rd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 4th (the machine can travel at 3rd).
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31604 ECMV 3 DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
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40 Troubleshooting SEN00739-01
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Action code Failure code R clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH7KY (Transmission controller system)
Contents of • Since the R (Reverse) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the R (Reverse) ECMV solenoid output was OFF.
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional
switch is in R (Reverse).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel only at R (reverse).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
Related
toring function (Code: 31606 ECMV R DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
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Action code Failure code F clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH8KY (Transmission controller system)
Contents of • Since the F (Forward) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the F (Forward) ECMV solenoid output was OFF.
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional
switch is in F (Forward).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine can travel only at F (forward).
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31608 ECMV F DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
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Action code Failure code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 4th clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
(Code: 31605 ECMV 4 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or move the
gear shift lever to 4th.
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Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with
power supply line) 1
Action code Failure code 4th clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 4th clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 3rd (the machine can travel at 4th).
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
Related
(Code: 31605 ECMV 4 DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.
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Action code Failure code 3-spool valve extract EPC solenoid: Disconnection
Trouble
E03 DXHJKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) extract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) extract EPC solenoid output is ON.
• Continues outputting.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The 3-spool valve (attachment) cylinder is not extracted.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
information
with the monitoring function (Code: 41906 3RD EPC1 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F21 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness
Wiring harness between L07 (female) (3) – Resis-
value in normal 2 (Disconnection in wiring Max. 1 z
state F21 (female) (2) tance
harness and defective
contact) Wiring harness between L07 (female) (25) – Resis-
Max. 1 z
F21 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 z
36 WA500-6
40 Troubleshooting SEN00739-01
Action code Failure code 3-spool valve extract EPC solenoid: Short circuit
Trouble
E03 DXHJKB (Work equipment controller system)
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) extract EPC solenoid
trouble
output was ON.
• The output to the 3-spool valve (attachment) extract EPC solenoid is stopped.
Action of • Stops outputting the signal to all work equipment detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
• The wiring harness or controller may be burnt out.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
information
with the monitoring function (Code: 41906 3RD EPC1 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F21 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L07 (female) (25) – Resis-
Min. 1 Mz
F21 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 z
WA500-6 37
SEN00739-01 40 Troubleshooting
Action code Failure code 3-spool valve extract EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHJKY (Work equipment controller system)
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
power source, abnormal voltage was applied when the 3-spool valve (attachment) extract EPC sole-
trouble
noid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
• The 3-spool valve (attachment) extract EPC solenoid may be burnt out.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
information
with the monitoring function (Code: 41906 3RD EPC1 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Turn starting switch ON.
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F21 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting.
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (25) –
Voltage Max. 1 V
F21 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 z
38 WA500-6
40 Troubleshooting SEN00739-01
Action code Failure code 3-spool valve retract EPC solenoid: Disconnection
Trouble
E03 DXHKKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) retract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) retract EPC solenoid output is ON.
• Continues outputting.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The 3-spool valve (attachment) cylinder is not retracted.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
information
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness
Wiring harness between L07 (female) (3) – Resis-
value in normal 2 (Disconnection in wiring Max. 1 z
state F22 (female) (2) tance
harness and defective
contact) Wiring harness between L07 (female) (35) – Resis-
Max. 1 z
F22 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 z
WA500-6 39
SEN00739-01 40 Troubleshooting
Action code Failure code 3-spool valve retract EPC solenoid: Short circuit
Trouble
E03 DXHKKB (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) retract EPC solenoid
trouble
output was ON.
• The output to the 3-spool valve (attachment) retract EPC solenoid is stopped.
Action of • Stops outputting the signal to all work equipment detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
• The wiring harness or controller may be burnt out.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
information
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal short circuit) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L07 (female) (35) – Resis-
Min. 1 Mz
F22 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 z
40 WA500-6
40 Troubleshooting SEN00739-01
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit
with power supply line) 1
Action code Failure code 3-spool valve retract EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHKKY (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the
Contents of
power source, abnormal voltage was applied when the 3-spool valve (attachment) retract EPC sole-
trouble
noid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
• The 3-spool valve (attachment) retract EPC solenoid may be burnt out.
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
information
with the monitoring function (Code: 41907 3RD EPC2 DIR).
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Start engine.
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal short circuit) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting.
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (35) –
Voltage Max. 1 V
F22 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 z
WA500-6 41
SEN00739-01 40 Troubleshooting
Action code Failure code Joystick steering right EPC solenoid: Disconnection
Trouble
E03 DXHLKA (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering right EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable. (Operable in handle mode.)
machine
• The output state (current) to the joystick steering right EPC solenoid can be checked with the moni-
toring function (Code: 41904 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to right.
Related
• Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring func-
information
tion (Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB or D193KY) is dis-
played, carry out troubleshooting for joystick steering solenoid cut relay system first.
42 WA500-6
40 Troubleshooting SEN00739-01
WA500-6 43
SEN00739-01 40 Troubleshooting
Action code Failure code Joystick steering right EPC solenoid: Short circuit
Trouble
E03 DXHLKB (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is short with the chassis ground, no current
trouble flows when the joystick steering right EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable. (Operable in handle mode.)
machine
• The output state (current) to the joystick steering right EPC solenoid can be checked with the moni-
toring function (Code: 41904 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to right.
Related
• Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring func-
information
tion (Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB or D193KY) is dis-
played, carry out troubleshooting for joystick steering solenoid cut relay system first.
44 WA500-6
40 Troubleshooting SEN00739-01
WA500-6 45
SEN00739-01 40 Troubleshooting
Action code Failure code Joystick steering right EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHLKY (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system was shorted with the power source, abnormal
trouble voltage was applied when the joystick steering right EPC solenoid output was OFF.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable. (Operable in handle mode.)
machine
• The output state (current) to the joystick steering right EPC solenoid can be checked with the moni-
Related
toring function (Code: 41904 J/S EPC DIR RH).
information
• Method of reproducing failure code: Turn the starting switch ON.
46 WA500-6
40 Troubleshooting SEN00739-01
WA500-6 47
SEN00739-01 40 Troubleshooting
Action code Failure code Joystick steering left EPC solenoid: Disconnection
Trouble
E03 DXHMKA (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering left EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable. (Operable in handle mode.)
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitor-
ing function (Code: 41905 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to left.
Related
• Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring func-
information
tion (Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB or D193KY) is dis-
played, carry out troubleshooting for joystick steering solenoid cut relay system first.
48 WA500-6
40 Troubleshooting SEN00739-01
WA500-6 49
SEN00739-01 40 Troubleshooting
Action code Failure code Joystick steering left EPC solenoid: Short circuit
Trouble
E03 DXHMKB (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is short with the chassis ground, no current
trouble flows when the joystick steering left EPC solenoid output is ON.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable. (Operable in handle mode.)
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitor-
ing function (Code: 41905 J/S EPC DIR RH).
• Method of reproducing failure code: Start engine and operate joystick steering to left.
Related
• Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring func-
information
tion (Code: 40953, D-OUT-8).
• If failure code of joystick steering solenoid cut relay system (D193KA, D193KB or D193KY) is dis-
played, carry out troubleshooting for joystick steering solenoid cut relay system first.
50 WA500-6
40 Troubleshooting SEN00739-01
WA500-6 51
SEN00739-01 40 Troubleshooting
Action code Failure code Joystick steering left EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHMKY (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system was shorted with the power source, abnormal
trouble voltage was applied when the joystick steering left EPC solenoid output was OFF.
• Stops the output to the joystick steering right and left EPC solenoids.
Action of • Stops the output to the joystick steering solenoid cut relay.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Joystick steering is inoperable. (Operable in handle mode.)
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitor-
Related
ing function (Code: 41905 J/S EPC DIR RH).
information
• Method of reproducing failure code: Turn the starting switch ON.
52 WA500-6
40 Troubleshooting SEN00739-01
WA500-6 53
SEN00739-01
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 08-06 (01)
54
SEN00740-03
WA500-6
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 3
Before carrying out troubleshooting of electrical system...................................................................... 3
Information in troubleshooting table ..................................................................................................... 6
E-1 Engine does not start..................................................................................................................... 7
E-2 Wiper does not operate ............................................................................................................... 12
E-3 Windshield washer does not operate .......................................................................................... 16
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off........................ 19
E-5 Working lamp does not light up or go off ..................................................................................... 27
E-6 Turn signal lamp and hazard lamp do not light up or go off......................................................... 32
E-7 Brake lamp does not light or it keeps lighting up ......................................................................... 38
E-8 Backup lamp does not light or it keeps lighting up ...................................................................... 40
E-9 Backup buzzer does not sound or it keeps sounding .................................................................. 42
E-10 Horn does not sound or it keeps sounding ................................................................................ 44
E-11 Alarm buzzer does not sound or it keeps sounding ................................................................... 47
WA500-6 1
SEN00740-03 40 Troubleshooting
2 WA500-6
40 Troubleshooting SEN00740-03
Fuse box A
Capacity of
Type of power supply Fuse No. Destination of power
fuse
Switch power supply
1 5A Engine controller circuit
Starting switch ACC
2 10 A Starting switch terminal B circuit
3 30 A Engine controller cut circuit
Constant power 4 10 A Hazard lamp circuit
supply
5 10 A Radio, auto grease circuit
slow blow fuse SBF1
(50 A) 6 10 A Transmission controller (B) circuit
7 10 A Work equipment controller (B) circuit
8 10 A Machine monitor (B) circuit
9 10 A Horn circuit
10 20 A Air conditioner circuit
WA500-6 3
SEN00740-03 40 Troubleshooting
Fuse box B
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1 10 A Turn signal lamp circuit
2 10 A Back-up lamp and brake lamp circuit
3 20 A Front working lamp circuit
4 20 A Rear working lamp circuit
SBF2 Turn signal lamp circuit, back-up lamp, brake lamp circuit, front
Switch power supply working lamp circuit. rear working lamp circuit, transmission con-
120 A troller (A) circuit, parking brake circuit, work equipment controller
(A) circuit, machine monitor (A) circuit, wiper, washer circuit,
spare, main lamp circuit
SBF3 250 A Heater relay circuit
4 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 5
SEN00740-03 40 Troubleshooting
6 WA500-6
40 Troubleshooting SEN00740-03
Contents of
• The engine does not start.
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 2 fuse of fuse box A is normal.
(If it is broken, check the related wiring harness for grounding fault.)
• The input state (ON/OFF) from starting switch terminal C to the machine monitor can be checked with
Related the monitoring function (Code: 40900, D-IN-7).
information • The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
with the monitoring function (Code: 40905, D-IN-7).
• The input state (ON/OFF) from starting switch terminal C to work equipment controller can be
checked with the monitoring function (Code: 40912, D-IN-17).
• If failure code [D5ZHKA], [D5ZHKB], [D5ZHKZ], [DDK3KA], [DDK3KB], [DDK4KA], [DDK4KB],
[DDK6KA], or [DDK6KB] is displayed, carry out troubleshooting for it first.
WA500-6 7
SEN00740-03 40 Troubleshooting
8 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 9
SEN00740-03 40 Troubleshooting
10 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 11
SEN00740-03 40 Troubleshooting
Contents of
(1) Front wiper does not operate.
trouble
Related
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
information
12 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 13
SEN00740-03 40 Troubleshooting
Contents of
(2) Rear wiper does not operate.
trouble
Related
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information
14 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 15
SEN00740-03 40 Troubleshooting
Contents of
Windshield washer does not operate
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)
16 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 17
SEN00740-03 40 Troubleshooting
18 WA500-6
40 Troubleshooting SEN00740-03
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light
up or go off 1
Contents of
(1) None of headlamp, clearance lamp, tail lamp, and license lamp lights up.
trouble
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
information
with the monitoring function (Code: 40200, SMALL LAMP).
• The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked
with the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be
checked with the monitoring function (Code: 40904 D-IN-34).
WA500-6 19
SEN00740-03 40 Troubleshooting
Contents of
(2) Either of headlamp low and high beams does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
• When the clearance lamp, tail lamp, and license lamp light up and go off normally.
Related • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked
information with the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be
checked with the monitoring function (Code: 40904 D-IN-34).
20 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 21
SEN00740-03 40 Troubleshooting
Contents of
(3) Headlamp low beam does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• When the high beam lights up (goes off) normally.
Related
• The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked
information
with the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be
checked with the monitoring function (Code: 40904 D-IN-34).
22 WA500-6
40 Troubleshooting SEN00740-03
Contents of
(4) Headlamp high beam does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• When the low beam lights up (goes off) normally.
Related
• The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked
information
with the monitoring function (Code: 40900 D-IN-0).
• The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be
checked with the monitoring function (Code: 40904 D-IN-34).
WA500-6 23
SEN00740-03 40 Troubleshooting
24 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 25
SEN00740-03 40 Troubleshooting
26 WA500-6
40 Troubleshooting SEN00740-03
Contents of
(1) Either of front working lamp and rear working lamp does not light up
trouble
• The working lamp system power supply wiring harness is disconnected or shorted with the chassis
Related ground.
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.
Contents of
(2) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related • When the rear working lamp lights up (goes off).
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.
WA500-6 27
SEN00740-03 40 Troubleshooting
28 WA500-6
40 Troubleshooting SEN00740-03
Contents of
(3) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related • When the front working lamp and side working lamp (OPT) light up (goes off).
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.
WA500-6 29
SEN00740-03 40 Troubleshooting
30 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 31
SEN00740-03 40 Troubleshooting
E-6 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (right turn signal lamp) to
Related
machine monitor can be checked with the monitoring function (Code: 40901, D-IN-12).
information
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to
machine monitor can be checked with the monitoring function (Code: 40901, D-IN-13).
32 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 33
SEN00740-03 40 Troubleshooting
Contents of
(2) Turn signal lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
When the hazard lamp blinks.
Related • The input state (ON/OFF) from turn signal lamp and hazard lamp switch (right turn signal lamp) to
information machine monitor can be checked with the monitoring function (Code: 40901, D-IN-12).
• The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to
machine monitor can be checked with the monitoring function (Code: 40901, D-IN-13).
34 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 35
SEN00740-03 40 Troubleshooting
Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp is defective.
information When the turn signal lamp flashes normally.
36 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 37
SEN00740-03 40 Troubleshooting
Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
• The lamp or wiring harness of the brake lamp system is abnormal.
information
38 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 39
SEN00740-03 40 Troubleshooting
Contents of
Backup lamp does not light or it keeps lighting up
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related
(If disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code
information
[D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)
Ground fault in wiring harness Wiring harness between L101 (female) (3) – Resis-
5
(Short circuit with ground circuit) G01 (female) (2), – G02 (female) (2) and tance
Min. 1 Mz
chassis ground
Wiring harness between L04 (female) (18) –
L101 (female) (1) and chassis ground Resis-
Min. 1 Mz
• If any abnormality is detected, failure code tance
[D160KZ] is displayed.
40 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 41
SEN00740-03 40 Troubleshooting
Contents of
Backup buzzer does not sound or it keeps sounding
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related
(If disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code
information
[D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)
42 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 43
SEN00740-03 40 Troubleshooting
Contents of
Horn does not sound or it keeps sounding (Steering wheel specification)
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information
44 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 45
SEN00740-03 40 Troubleshooting
46 WA500-6
40 Troubleshooting SEN00740-03
Contents of
• Alarm buzzer does not sound or it keeps sounding
trouble
• The alarm buzzer output circuit is disconnected or shorted with the chassis ground.
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: 40952, D-OUT-0).
• If failure code [DV00KB] (Alarm buzzer: Short circuit) is displayed, carry out troubleshooting for it first.
WA500-6 47
SEN00740-03 40 Troubleshooting
48 WA500-6
40 Troubleshooting SEN00740-03
Contents of
Air conditioner does not operate or stop.
trouble
• The following is troubleshooting for only the power supply or ground circuit between the air condi-
Related
tioner and operator's cab. For troubleshooting for the other item, see "Air conditioner" on chapter 80,
information
"Appendix".
WA500-6 49
SEN00740-03 40 Troubleshooting
50 WA500-6
40 Troubleshooting SEN00740-03
WA500-6 51
SEN00740-03 40 Troubleshooting
52 WA500-6
40 Troubleshooting SEN00740-03
CPU LED
1. LED-C1 (R signal and ACC signal status)
2. LED-C2 (engine control signal status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (download writing condition)
6. LED-C6 (download writing condition)
7 segments and dot for CPU
7. 7 segments (number of mails not yet sent)
8. Dot (GPS positioning in progress)
WA500-6 53
SEN00740-03
© 2018 KOMATSU
All Rights Reserved
Printed in Japan 06-18 (01)
54
SEN00741-00
WA500-6
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
Table of failure modes and causes....................................................................................................... 6
H-1 Machine does not start ................................................................................................................ 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)] .................................................................................. 12
H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)] ............ 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak,
and gear is not shifted................................................................................................................. 14
H-5 Shocks are large at the times of starting and shifting gear.......................................................... 16
H-6 Time lag is large at the times of starting and shifting gear .......................................................... 18
H-7 Torque converter oil temperature is high ..................................................................................... 20
H-8 Steering does not turn ................................................................................................................. 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)].......................................... 22
WA500-6 1
SEN00741-00 40 Troubleshooting
2 WA500-6
40 Troubleshooting SEN00741-00
WA500-6 3
SEN00741-00 40 Troubleshooting
3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the cause column. taken the action given in the remedy line.
In the same way as in Step 2, if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the ×: Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
b or e.)
4 WA500-6
40 Troubleshooting SEN00741-00
WA500-6 5
SEN00741-00 40 Troubleshooting
Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] Q
Travel speed is slow, thrusting force is weal, uphill traveling power is weak, and gear is not shifted Q Q Q Q Q Q Q Q Q
Shocks are large at the times of starting and shifting gear Q Q Q Q
Time lag is large at the times of starting and shifting gear Q Q Q Q
Torque converter oil temperature is high Q Q Q Q Q Q Q
Steering does not turn Q
Steering does not turn [Machine with joystick steering (if equipped)] Q
Steering response is low Q
Steering
Turning response of steering is poor [machine with joystick steering (if equipped)] Q
Steering is heavy
When machine turns, it shakes or makes large shocks
When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]
Wheel brake does not work or does not work well Q
Wheel brake is not released or it drags
Brake
6 WA500-6
Clogging of last chance filter
Q Q
Q Q
Q Q
Q
Q Q
Defective operation of relevant ECMV
Q Q Q
Defect of transmission controller system
WA500-6
Q
Q
Internal breakage of transmission
Q Q
Q
Q Q
Wear or seizure of relevant clutch disc
Defective clutch piston
The relevant clutch piston seal is defective
40 Troubleshooting
Q Q
Q Q Q
Q Q
Q Q
Defective seal of relevant clutch shaft
Q
Q Q Q
Clogging of transmission breather
Q
Q
Defective transmission oil temperature sensor
Q
Defective transmission output shaft speed sensor
Defective seal of work equipment and steering
Q
Q
system hydraulic pump shaft
Clogging or air intake on steering pump suction side
Q Q
Q Q
Defective steering pump
Q Q
Defective steering pump servo
Defective Orbit-roll
Q Q
Defective steering stop valve
Defective steering main relief valve
Defective demand spool
Q
Defective steering spool of steering valve
Defective safety-suction valve
Q Q Q Q Q
Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective seal of steering cylinder piston
Clogging of joystick steering solenoid valve line filter
Defective joystick steering solenoid valve
Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective actuation of rotary valve
Q
Defective steering wheel or steering shaft
Defective seal of brake piston
Q
Defective operation of brake piston
Internal breakage of wheel brake
Q Q Q Q
Wear of wheel brake disc
Q
Seized wheel brake disc plate
Q
Q
Q
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
7
SEN00741-00
SEN00741-00 40 Troubleshooting
Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]
Travel speed is slow, thrusting force is weal, uphill traveling power is weak, and gear is not shifted
Shocks are large at the times of starting and shifting gear
Time lag is large at the times of starting and shifting gear
Torque converter oil temperature is high
Steering does not turn Q
Steering does not turn [Machine with joystick steering (if equipped)] Q
Steering response is low Q
Steering
Turning response of steering is poor [machine with joystick steering (if equipped)] Q
Steering is heavy Q
When machine turns, it shakes or makes large shocks Q
When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] Q
Wheel brake does not work or does not work well Q Q Q Q
Wheel brake is not released or it drags Q
Brake
8 WA500-6
Q
Q
Q
Q
The parking brake piston seal is defective
Q
Wear of parking brake disc
Q
Seizure of parking brake disc and plate
WA500-6
Defective harness of parking brake switch line
Q
Q
Q
Q
Q
Q
Q
Q
Q
suction side
Q
Defective work equipment controller
40 Troubleshooting
Q Q
Defective work equipment pump servo
Q
Q
Defective work equipment valve body
Defective work equipment main relief valve
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Defective work equipment unload valve
Q Q Q Q Q Q
Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Defective lift arm spool of work equipment valve
Q Q
Q Q
Q
Q
Q
Q
Q
Defective bucket spool of work equipment valve
Q
Q
Q
Q
Q
Q
equipment valve
Q
Q
of work equipment valve
Q
Q
Q
Q
Q
of work equipment valve
Q
Q
Q
Defective lift arm cylinder
Q
Defective bucket cylinder
Q
Q
Q
Q
Q
Defective seal of lift arm cylinder piston
Q
Q
Q
Q
Q
Q
Defective seal of bucket cylinder piston
Q
Defective stroke of lift arm EPC lever
Q
Defective stroke of bucket EPC lever
Q
lever
Q
linkage
Q
Defective ECSS solenoid valve
Q
Q
Q
Q
Q
Q
Q
Defective ECSS charge valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
9
SEN00741-00
SEN00741-00 40 Troubleshooting
Torque converter
Torque converter
Parking brake
o Seizure of clutch, breakage of parts
release valve
Transmission
Check valve
ECMV
Did the machine cause any abnormal noise
at the time and where?
Remedy E E E E E E E E E
No.
Diagnosis x C x
x
x x x
x * x
* * x
x x
x x
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
10 WA500-6
40 Troubleshooting SEN00741-00
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA500-6 11
SEN00741-00 40 Troubleshooting
H-2 Torque converter lockup is not switched off (engine stalls) [Machine
with lockup clutch (if equipped)] 1
Checks before troubleshooting Cause
q Is the oil level of transmission case appropriate? a b
12 WA500-6
40 Troubleshooting SEN00741-00
Remedy
E
No. Diagnosis Transmission x x x x C x
x
controller self-diagnosis code
1 Main relief oil pressure is low Q
2 Main relief oil pressure is normal, but lockup oil pressure is low or 0 Q Q Q Q Q
3 Main relief oil pressure and oil pressure is normal, but lockup oil pressure is low or 0 Q
4 Time to lockup actuation takes long 15SJLH Q
WA500-6 13
SEN00741-00 40 Troubleshooting
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power
is weak, and gear is not shifted 1
Ask the operator about the following: Cause
q Has the abnormality occurred suddenly?
Torque converter
Torque converter
Torque converter
Parking brake
Transmission
oil cooler
Others
ECMV
Did any abnormal noise occur at the time and
where?
q Have any abnormal signs come to occur gradually?
o Wear of related equipment, defective seal
a b c d e f g h i j k l m n o p q r s
Check of abnormality
q Execute digging and measure traveling speeds on
a level ground and on a slope to check whether the
clogged?
Clogging of breather
priate?
Remedy C E E E E E E E E C E
No. x x x * * x x
Diagnosis x x x x x x x x x x x
1 Any abnormality occurs at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Any abnormality occurs at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, the charging
3 Q Q
pump or the transmission filter causes any abnormal noise
4 The torque converter oil temperature is heated abnormally high Q Q Q Q Q Q Q Q Q Q Q Q
5 The transmission oil level rises and falls Q Q Q Q Q Q
Metal (Aluminum, copper, iron, etc.) powders are adhered to the
6 Q Q Q
transmission filter or the strainer
The engine low idle and high idle speeds are measured to be
7 Q Q Q
abnormal
8 When the stall speed of the The speed is high Q Q Q Q Q Q Q Q Q Q
9 torque converter is measured The speed is low Q
The oil pressure drops as the
10 Q Q Q Q
oil temperature rises
The oil pressure is low at all
11 Q Q Q Q Q Q Q Q Q
gear speeds
When the ECMV output (Clutch)
The oil pressure is low at spe-
12 oil pressure is measured Q Q Q Q
cific gear speeds
The oil pressure does not
13 become stable as the gauge Q Q
fluctuates
When the torque converter relief (Inlet) oil pressure is mea-
14 Q Q Q
sured, the oil pressure is low. (No. 11 - 13 are normal.)
When the oil pressure at the torque converter outlet is mea-
15 Q
sured, the oil pressure is low. (No. 14 is normal.)
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
14 WA500-6
40 Troubleshooting SEN00741-00
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA500-6 15
SEN00741-00 40 Troubleshooting
H-5 Shocks are large at the times of starting and shifting gear 1
Ask the operator about the following: Cause
q Did shocks become large suddenly?
Torque converter
Parking brake
Transmission
o Breakage of related equipment
Sensor
ECMV
Did any abnormal noise occur at the time and where?
q Did shocks become large gradually?
o Wear of related equipment, defective seal
Clogging of strainer
q Isn't the engine speed high at the time of low idle?
q Isn't play of each drive shaft large?
Remedy C E E
No.
Diagnosis x x
x
x
x * ** * * x x **
1 Shocks are large at all gear speeds Q Q Q Q Q Q Q Q
2 Shocks are large at specific gear speeds Q Q Q Q Q Q
3 When the ECMV output The oil pressure is low at all gear speeds Q Q Q Q Q Q
4 (Clutch) oil pressure is The oil pressure is low at specific gear speeds Q Q Q
5 measured The oil pressure is high at all gear speeds Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
* : Proceed to the paragraph of "Defective clutch and ECMV specifying method (Check by failure code)."
** : See "Troubleshooting by failure code (Display of code)."
16 WA500-6
40 Troubleshooting SEN00741-00
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA500-6 17
SEN00741-00 40 Troubleshooting
H-6 Time lag is large at the times of starting and shifting gear 1
Ask the operator about the following: Cause
q Did the time lag become large suddenly?
Torque converter
Parking brake
Transmission
o Breakage of related equipment
Sensor
ECMV
Did any abnormal noise occur at the time and where?
q Has the time lag become large gradually?
o Wear of related equipment, defective seal
Check of abnormality a b c d e f g h i j
q Did any of the following abnormal phenomena occur at the same time:
Clogging of strainer
q Is any external oil leak found on the mating faces of pipings and valves
around the torque converter and the transmission?
Remedy C E E
No. x
Diagnosis x x x
x
* * x x **
1 Time lag is large at all gear speeds Q Q Q Q Q Q Q
2 Time lag is large at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, any abnormal noise occurs from the
3 Q Q
charging pump or the transmission filter
4 The torque converter oil temperature is heated abnormally high Q Q Q Q
5 When the ECMV output (Clutch) The oil pressure is low at all gear speeds Q Q Q Q Q
6 oil pressure is measured The oil pressure is low at specific gear speeds Q Q Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
* : Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
** : See Troubleshooting by failure code (Display of code)
18 WA500-6
40 Troubleshooting SEN00741-00
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA500-6 19
SEN00741-00 40 Troubleshooting
Torque converter
Torque converter
Torque converter
Transmission
stalls and does the temperature fall at the time of no
oil cooler
Others
load? o Selection of improper gear speed
Did any abnormal noise occur at the time and where?
q Does the oil temperature rise only at the time of lifting?
o Improvement of operating method
a b c d e f g h i j k l
Check of abnormality
Clogging of breather
Remedy C E E EEEE C E
No. x x
Diagnosis x x x x x x x x x
When the transmission oil temperature is low, the charging
1 Q Q
pump or the transmission filter causes any abnormal noise
Traveling speed, braking force and uphill travelling power do not
2 Q Q Q Q Q Q Q Q Q Q Q
occur at all gear speeds
Traveling speed, braking force and uphill travelling power do not
3 Q
occur at specific gear speeds
4 The transmission oil level rises and falls Q Q Q
Metal powders (Aluminum, copper, iron, etc.) are adhered to the
5 Q Q Q
transmission filter and the strainer
The engine low idle and high idle speeds are measured to be
6 Q Q Q
abnormal
When the stall speed of the torque converter is measured, the
7 Q Q Q Q Q Q Q Q Q
speed is high
The oil pressure drops as the oil tem-
8 Q
perature rises
The oil pressure is low at all gear
9 When the ECMV output speeds Q Q Q Q Q
(Clutch) oil pressure is
The oil pressure is low at specific gear
10 measured Q
speeds
The oil pressure does not become sta-
11 Q Q
ble as the gauge vibrates
When the torque converter relief (Inlet) oil pressure is mea-
12 Q Q Q
sured, the oil pressure is low. (No. 9 - 11 are normal.)
When the oil pressure at the torque converter outlet is mea-
13 Q
sured, the oil pressure is low. (No. 12 is normal.)
20 WA500-6
40 Troubleshooting SEN00741-00
Hydraulic cylinder
q
Hydraulic pump
Steering valve
Charge valve
Did the machine cause any abnormal noise at the time and where?
Stop valve
Orbit-roll
Checks before troubleshooting
q Is oil level in hydraulic tank correct? Is the type of oil correct?
q Is the steering shaft broken?
q Is the steering stop valve properly adjusted? a b c d e f g h i j k
q Has the lock bar been removed from the frame?
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is left in the steering, check the operation of the work equipment also.
WA500-6 21
SEN00741-00 40 Troubleshooting
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 1
Ask the operator about the following: Cause
Hydraulic cylinder
q Did the problem suddenly start?
Joystick steering
Hydraulic pump
solenoid valve
Steering valve
Charge valve
o Breakage of related equipment
Rotary valve
Did the machine cause any abnormal noise at the time and where?
22 WA500-6
40 Troubleshooting SEN00741-00
Hydraulic cylinder
q Did the problem suddenly start?
Hydraulic pump
Steering valve
Charge valve
o Breakage of related equipment
Stop valve
Orbit-roll
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m
Checks before troubleshooting
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is left in the steering, check the operation of the work equipment also.
WA500-6 23
SEN00741-00 40 Troubleshooting
Hydraulic cylinder
q Did the problem suddenly start?
Joystick steering
Steering pump
solenoid valve
Steering valve
Charge valve
o Breakage of related equipment
Rotary valve
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m n
Checks before troubleshooting
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is left in the steering, check the operation of the work equipment also.
24 WA500-6
40 Troubleshooting SEN00741-00
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
Others
Measure the operating effort and turning speed, and check the “Standard value table” to
see if they are abnormal.
WA500-6 25
SEN00741-00 40 Troubleshooting
Hydraulic pump
q
Steering valve
Charge valve
Stop valve
q Is there any abnormal noise from around the steering equipment
Orbit-roll
Cylinder
Checks before troubleshooting
q Is the steering wheel play correct?
q Is there any abnormality in the connection between the steering shaft and
a b c d e f g h i
the Orbit-roll?
26 WA500-6
40 Troubleshooting SEN00741-00
Hydraulic pump
Steering valve
Checks before troubleshooting
Charge valve
Rotary valve
Cylinder
q Has the machine monitor displayed any failure code?
o See Troubleshooting by failure code (Display of code)
q Is the steering play proper?
q Is there any abnormality in the connection between the steering shaft and
the Orbit-roll?
q Is the tire inflation pressure correct?
a b c d e f g h i
Remedy E E EEE EE
No. x E
Diagnosis x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one direction (left or right) Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
4 Work equipment also jerks Q Q
5 When steering relief Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q Q
6 pressure is measured Oil pressure is unstable in one direction (left or right) Q
7 When Orbit-roll output Oil pressure is unstable in both directions (left and right) Q Q Q Q
8 pressure is measured Oil pressure is unstable in one direction (left or right)
9 When Orbit-roll basic pressure is measured, oil pressure is found to be unstable Q Q
WA500-6 27
SEN00741-00 40 Troubleshooting
H-15 Wheel brake does not work or does not work well 1
Check of abnormality Cause
Slack adjuster
q Test the effectiveness of the brake referring to “Measuring brake
Charge valve
Wheel brake
Accumulator
Brake pump
Brake valve
performance” in “Testing and adjusting” to check whether the
Others
abnormality actually occurs or is a matter of operator's sense
28 WA500-6
40 Troubleshooting SEN00741-00
Slack adjuster
q
Wheel brake
Brake valve
Did the machine cause any abnormal noise at the time and where?
WA500-6 29
SEN00741-00 40 Troubleshooting
H-17 Parking brake does not work or does not work well 1
Ask the operator about the following: Cause
Has the brake come not to work suddenly? o Breakage of related equipment
Parking brake
q
Solenoid
Did the machine cause any abnormal noise at the time and where?
Valve
q Has the brake come not to work gradually?
o Wear of related equipment, defective seal
30 WA500-6
40 Troubleshooting SEN00741-00
Parking brake
q Is there any abnormality in the power train system?
o See H-1, H-4, H-5 and H-6 (Power train hydraulic system)
Solenoid
Wheel
Valve
a b c d e
a If any abnormality is left in releasing of the parking brake, check the operation of the power train also,
because the power train main relief pressure is used as the parking brake release pressure. (The
emergency release circuit uses the wheel brake circuit oil pressure.)
WA500-6 31
SEN00741-00 40 Troubleshooting
equipment pump
q
Work equipment
Bypass valve
Tank – Work
o Seizure or breakage of each component
Cylinder
valve
Did abnormal sound come out when the lift arm stopped?
(From what part)
q Has the speed lowered? o Wear of parts and fatigue of springs
32 WA500-6
40 Troubleshooting SEN00741-00
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1
Checks before troubleshooting Cause
Is the stroke of the lift arm control lever proper?
equipment pump
q
Work equipment
Tank – Work
q Is the engine speed proper?
Cylinder
valve
Check of abnormality
q The troubles of the rising force and rising speed are strongly related to each
other. The rising speed lowers first. Measure the lift arm rising speed while it
is loaded and check abnormality with the “Standard value table.” a b c d e f g h i
WA500-6 33
SEN00741-00 40 Troubleshooting
H-21 When rising, lift arm comes to move slowly at specific height 1
Checks before troubleshooting
q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-20 Lift arm speed is low or rising force of lift
arm is insufficient“
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) 1
See “H-20 Lift arm speed is low or rising force of lift arm is insufficient.”
34 WA500-6
40 Troubleshooting SEN00741-00
equipment pump
q
Work equipment
Tank – Work
o Seizure or breakage of each component
Cylinder
valve
Did abnormal sound come out when the bucket stopped?
(From what part)
q Has the speed lowered? o Wear of parts and fatigue of springs
C
Remedy C E E E E E E
No. E x x
Diagnosis E x x x x x x
x
1 Lift arm does not move and bucket does not tilt back Q Q Q Q Q
2 Bucket can raise chassis but does not tilt back Q Q
3 Lift arm moves but bucket does not tilt back Q Q
4 Bucket can tilt back when not loaded but cannot when used for digging or scooping Q Q Q Q Q Q
5 Work equipment pump is making abnormal sound Q Q
6 Hydraulic drift of bucket cylinder is large Q Q Q Q
7 When lift arm and bucket are operated simultaneously, bucket does not tilt back Q
8 When work equipment pump and servo assembly is replaced, bucket moves normally Q
WA500-6 35
SEN00741-00 40 Troubleshooting
equipment pump
q
Work equipment
Tank – Work
q Is the engine speed proper?
Cylinder
valve
Check of abnormality
q Check by actual operation that the tilting back force is insufficient.
q Measure the operating speed of the bucket and check it with the “Stan-
dard value table.” a b c e f g h i j k
A C
Remedy C E E EEE
No. E E x x
Diagnosis E x x x x x
x x
Rising force and speed of lift arm are abnormal and tilting back force and speed of
1 Q Q Q Q Q Q
bucket are low
Rising force and speed of lift arm are normal and tilting back force and speed of
2 Q Q Q Q
bucket are low
3 After oil temperature rises, tilting back speed lowers more in step 1. Q
4 Work equipment pump is making abnormal sound Q Q
5 Hydraulic drift of the cylinder is large Q Q Q Q
6 Relief oil pressure of relief valve of work equipment valve is low Q Q Q Q Q Q Q
7 When work equipment pump and servo assembly is replaced, bucket moves normally Q
36 WA500-6
40 Troubleshooting SEN00741-00
H-30 Bucket wobbles during travel with cargo (Work equipment valve is
set to “HOLD”) 1
Cause
q Defective seal of bucket cylinder piston
q Defective operation of safety valve (With suction valve) on bucket cylinder head side. For other abnor-
mal phenomena, refer to diagnoses for relevant abnormal phenomena.
WA500-6 37
SEN00741-00 40 Troubleshooting
H-32 Large shocks are made when work equipment starts and stops 1
Cause
q Defective operation of control valve spool
q Defective working equipment electric lever system
o See Troubleshooting by failure code (Display of code)
38 WA500-6
40 Troubleshooting SEN00741-00
H-34 ECSS does not operate, and pitching and bouncing occur 1
Ask the operator about the following: Cause
Did pitching and bouncing occur suddenly? o Breakage of related equipment
Solenoid valve
q
Accumulator
Controller
Did any abnormal noise occur at the time and where?
Sensor
q Has pitching and bouncing occurred gradually? o Wear of related equipment, defective seal
WA500-6 39
SEN00741-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 03-06 (01)
40
SEN00742-03
WA500-6
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
S-1 Engine does not start easily........................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 8
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operation ..................................................................................................... 13
S-5 Engine does not rotate smoothly (Engine hunts.)........................................................................ 14
S-6 Engine lacks output (or lacks power)........................................................................................... 15
S-7 Exhaust smoke is black (Incomplete combustion)....................................................................... 16
S-8 Oil is consumed much (or exhaust gas color is blue) .................................................................. 18
S-9 Engine oil becomes contaminated quickly................................................................................... 19
S-10 Fuel consumption is excessive.................................................................................................. 20
S-11 Coolant contains oil (blows back or reduces) ............................................................................ 21
S-12 Oil pressure drops ..................................................................................................................... 22
S-13 Oil level rises (Water, fuel in oil) ................................................................................................ 23
S-14 Coolant temperature rises too high (Overheating) .................................................................... 25
WA500-6 1
SEN00742-03 40 Troubleshooting
2 WA500-6
40 Troubleshooting SEN00742-03
Questions:
Sections A + B in the right corresponds to the items
were answers can be obtained from the user or
operator.
A is the basic content. B is the items that can be
obtained from the user or operator depending on
their level.
Check items:
Simple items checked by the serviceman to deter-
mine the causes. C in the chart to the right corre-
sponds to them.
Causes:
The contents to be determined after asking ques-
tions and checking items.
The serviceman determines causes of high proba-
bility from A, B, and C.
Troubleshooting:
The content for ultimately verifying whether the
determined causes are truly the defective factors
by using troubleshooting tools or making direct
checking starting with probable causes of higher
order.
This troubleshooting chart marks the content of the
questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
WA500-6 3
SEN00742-03 40 Troubleshooting
4 WA500-6
40 Troubleshooting SEN00742-03
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes.
Procedure for determining the causes from these relationship and leading to the troubleshooting will be
explained in step 1 to 3 in the following diagram.
WA500-6 5
SEN00742-03 40 Troubleshooting
Defective injector
state, however.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 WA500-6
40 Troubleshooting SEN00742-03
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA500-6 7
SEN00742-03 40 Troubleshooting
Degree of machine
Machine operated for long period EEE
operation
Condition of horn when Does not sound. Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
No operating sound from battery relay when starting switch is turned ON Q w
When starting switch is turned to START, pinion does not move out Q Q w
Check items
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to flow out
q
(*1)
Carry out troubleshooting on
Replace
Replace
Replace
Replace
Correct
Remedy
8 WA500-6
40 Troubleshooting SEN00742-03
WA500-6 9
SEN00742-03 40 Troubleshooting
Air is discharged when the air is bled from the fuel system q
q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA271], and Code [CA272]
*3: Troubleshooting by failure code (Display of code), Code [CA273], and Code [CA274]
10 WA500-6
40 Troubleshooting SEN00742-03
c) Exhaust smoke comes out but engine does not start Cause
When engine is and the air breathing plug is removed from the fuel filter, fuel
Q w w
cranked with starting fails to discharge
motor, Spill flow drops, when spill hose is separated from injector w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter, strainer directly q
Inspect fuel feed pump gauze filter directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q
Testing a single unit injector indicates defective spraying q
Specific gravity of electrolyte and voltage of battery are low q
Coolant temperature gauge indication is not normal (when the gauge is installed) q
Intake air heater mount does not warm up during preheating operation q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA500-6 11
SEN00742-03 40 Troubleshooting
Black w Q w w
When engine is cranked, abnormal noise is heard from around cylinder head w
When engine is cranked, abnormal noise is heard from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
12 WA500-6
40 Troubleshooting SEN00742-03
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Add
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA500-6 13
SEN00742-03 40 Troubleshooting
Air is discharged when the air is bled from the fuel system q
Inspect fuel feed pump gauze filter directly q
Inspect the fuel filter, strainer directly q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Carry out troubleshoot by “Eng Ne Speed Sensor Error (*3)” q
Carry out troubleshoot by “Eng Ne Speed Sensor Error (*4)” q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Add
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: Troubleshooting by failure code (Display of code), Code [CA1628], and Code [CA1629]
*3: Troubleshooting by failure code (Display of code), Code [CA689]
*4: Troubleshooting by failure code (Display of code), Code [CA778]
14 WA500-6
40 Troubleshooting SEN00742-03
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA122], and Code [CA123]
*3: Troubleshooting by failure code (Display of code), Code [CA263], and Code [CA265]
WA500-6 15
SEN00742-03 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
16 WA500-6
40 Troubleshooting SEN00742-03
*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: EGR gas pressure piping
Remove 2 EGR gas pressure pipes (2) and check the clogging in the inside.
*3: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*4: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]
WA500-6 17
SEN00742-03 40 Troubleshooting
Turbocharger
Worn or damaged valve (stem, guide, and seal)
q Extended operation for long hours in low or high
idle (continuous no load operation for 20 minutes
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
18 WA500-6
40 Troubleshooting SEN00742-03
operation
Non-specified fuel is being used Q
Engine oil replenishment increasing Q w
Oil filter clogging monitor indicates clogging when the oil temperature rises (with the
w Q
monitor installed)
Metal particles are found when oil is drained in oil filter Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
w
Check items
When compression pressure is measured, the oil pressure is low q q (See S-7)
Inspect breather, breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
There is catching or breakage to the oil filter safety valve spring q
Inspect turbocharger lubricating drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Remedy
WA500-6 19
SEN00742-03 40 Troubleshooting
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]
20 WA500-6
40 Troubleshooting SEN00742-03
q
Troubleshooting
Remedy
WA500-6 21
SEN00742-03 40 Troubleshooting
operation
Oil pressure monitor indicates low pressure level (with monitor installed) Q w
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation &
w
Maintenance Manual
Indicates a drop of hydraulic pressure during low idle w Q Q
Oil pressure monitor Indicates a drop of oil pressure during low and high Q w w w Q Q Q
(With monitor idle
installed) Indicates a drop of oil pressure on a slope w
Indicates a drop of oil pressure occasionally w Q Q
Oil level monitor indicates low level (with monitor installed) w w
Oil pan oil level is in short w
w w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
—
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA135], and Code [CA141]
22 WA500-6
40 Troubleshooting SEN00742-03
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to
q
flow out (*1)
When compression pressure is measured, the oil pressure is low q
q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA500-6 23
SEN00742-03 40 Troubleshooting
24 WA500-6
40 Troubleshooting SEN00742-03
operation
Suddenly increased Q Q w
Condition of overheating
Always tends to overheat Q w w
q
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Correct
Add
Remedy
WA500-6 25
SEN00742-03 40 Troubleshooting
Gradually increased Q Q
Condition of abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is being used Q
Engine oil must be added more frequently w
Metal particles are found when oil is drained in oil filter w w
Leakage of air between turbocharger and cylinder head w
When engine is cranked, abnormal noise is heard from around turbocharger w
When engine is cranked, abnormal noise is heard from around EGR gas piping w
When engine is cranked, abnormal noise is heard from around cylinder head w w
When engine is cranked, abnormal noise is heard from around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
26 WA500-6
40 Troubleshooting SEN00742-03
Replace
Replace
Adjust
Adjust
Remedy
WA500-6 27
SEN00742-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
28
SEN02022-04
WA500-6
WA500-6 1
SEN02022-04 50 Disassembly and assembly
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
for the following.
79 T-
* *** ****
- :
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
2 WA500-6
50 Disassembly and assembly SEN02022-04
WA500-6 3
SEN02022-04 50 Disassembly and assembly
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 WA500-6
50 Disassembly and assembly SEN02022-04
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
WA500-6 5
SEN02022-04 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 WA500-6
50 Disassembly and assembly SEN02022-04
New/Remodel
Necessity
Sketch
Q'ty
Work item Symbol Part No. Part name Nature of work, remarks
WA500-6 7
SEN02022-04 50 Disassembly and assembly
New/Remodel
Necessity
Sketch
Q'ty
Work item Symbol Part No. Part name Nature of work, remarks
8 WA500-6
50 Disassembly and assembly SEN02022-04
New/Remodel
Necessity
Sketch
Q'ty
Work item Symbol Part No. Part name Nature of work, remarks
WA500-6 9
SEN02022-04 50 Disassembly and assembly
New/Remodel
Necessity
Sketch
Q'ty
Work item Symbol Part No. Part name Nature of work, remarks
1 793-520-2630 Bar t 2
2 793-520-2640 Push puller t 1
3 793-520-2550 Guide t 1
Press fitting of upper 4 790-101-2300 Push puller t 1
1
hinge pin 5 790-101-2310 • Block 1
6 02215-11622 • Nut 2
7 790-101-2102 Puller (294 kN {30 ton}) t 1
K
8 790-101-1102 Pump t 1
1 793-520-2530 Guide t 1
2 01010-31480 Bolt t 2
Press fitting of lower 3 01643-31445 Washer t 2
2
hinge pin 4 793-520-2640 Push puller t 1
5 790-101-2102 Puller (294 kN {30 ton}) t 1
6 790-101-1102 Pump t 1
1 790-502-1003 Repair stand t 1
1
2 790-101-1102 Pump 1
790-102-4300 Wrench assembly t 1 Removal and installation
2
790-102-4310 Pin t 2 of piston
Socket (Width across Removal and installation
3 790-302-1290 t 1
flats: 60 mm) of steering cylinder nut
1 790-201-1500 Push tool kit t 1 Press fitting of dust seal
2 790-201-1590 • Plate t 1 Steering cylinder
4 3 790-201-1680 • Plate 1 Bucket cylinder
4 790-101-5021 • Grip 1
All cylinders
5 01010-50816 • Bolt 1
Disassembly and assem- Press fitting of roll bush-
bly of hydraulic cylinder U 1 790-201-1702 Push tool kit t 1
ing
assembly
2 790-201-1781 • Push tool 1 Steering cylinder
5
3 790-201-1871 • Push tool 1 Bucket cylinder
4 790-101-5021 • Grip 1
All cylinders
5 01010-50816 • Bolt 1
1 790-720-1000 Expander t 1 Expansion of piston ring
2 796-720-1660 Ring t 1
Steering cylinder
3 07281-01159 Clamp t 1
6 4 796-720-1680 Ring t 1
Lift arm cylinder
5 07281-01589 Clamp t 1
6 796-720-1690 Ring t 1
Bucket cylinder
7 07281-01919 Clamp t 1
1 793-498-1120 Clear plate t 2
2 2 793-498-1130 Plate t 2 Installation of operator's
Operator's cab glass X
3 793-498-1110 Magnet t 2 cab glass
3 793-498-1210 Lifter (Suction cup) t 2
10 WA500-6
50 Disassembly and assembly SEN02022-04
WA500-6 11
SEN02022-04 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
12 WA500-6
50 Disassembly and assembly SEN02022-04
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
G5. Adapter
WA500-6 13
SEN02022-04 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
H1. Plate
14 WA500-6
50 Disassembly and assembly SEN02022-04
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
H2. Plate
H3. Fixture
WA500-6 15
SEN02022-04 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
H5. Plate
H5. Arm
16 WA500-6
50 Disassembly and assembly SEN02022-04
Note) We will not be liable for any result of use of special tools manufactured according to the following
drawings.
H7-2. Adapter
H15. Fixture
WA500-6 17
SEN02022-04
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 07-19 (01)
18
SEN02023-04
WA500-6
WA500-6 1
SEN02023-04 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02023-04
WA500-6 3
SEN02023-04 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
4 WA500-6
50 Disassembly and assembly SEN02023-04
12. Loosen the clamp and remove air connector and hose
assembly (8).
Tool: Socket wrench
Mounting clamp for air connector, hose (8): Width across
flats 9.5 mm (3/8 inch)
13. Loosen the clamp and remove tube (9) between the turbo-
charger and air aftercooler. [*1]
Tool: Socket wrench
Mounting clamp for tube (9): Width across flats 9.5 mm (3/8
inch)
14. Loosen hose clamps (10) between the air cleaner and tur-
bocharger and remove air cleaner band (11) and air cleaner
assembly (12). [*2]
Tool: Socket wrench
Hose clamp (10): Width across flats 8 mm
Air cleaner fixing band (11): Width across flats 17 mm
WA500-6 5
SEN02023-04 50 Disassembly and assembly
22. Disconnect hose (23) and remove the clamp and fuel return
tube (24). [*4]
Tools: Open-end wrench, special tool AB
Hose (23): Width across flats 22 mm, nominal 03
Tool: Socket wrench
Tube (24) clamp: Width across flats 17 mm, M10
Joint bolt for tube (24): Width across flats 19 mm, M14
6 WA500-6
50 Disassembly and assembly SEN02023-04
27. Remove cover (31) and disconnect engine drain valve (32).
Tool: Socket wrench
Mounting bolt for cover (31): Width across flats 19 mm, M12
Mounting bolt for drain valve (32): Width across flats
17 mm, M10
WA500-6 7
SEN02023-04 50 Disassembly and assembly
38. Remove right and left engine front mounting bolts (52). [*7]
Tool: Socket wrench
Mounting bolt (52): Width across flats 32 mm, M22
39. Remove right and left engine rear mounting bolts (53). [*8]
Tool: Socket wrench
Mount bolt (53): Width across flats 32 mm, M22
8 WA500-6
50 Disassembly and assembly SEN02023-04
40. Sling the engine assembly and remove mounting bolt (54).
[*9]
Tool: Socket wrench
Mounting bolt (54): Width across flats 19 mm, M12
WA500-6 9
SEN02023-04 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Tube clamp: Width across flats 9.5 mm (3/8 inch)
3 Tube clamp: 10.5 Nm {1.07 kgm}
[*2]
Tool: Torque wrench (socket)
Hose clamp: Width across flats 9.5 mm (3/8 inch)
3 Hose clamp: 10.5 Nm {1.07 kgm}
a When installing clamp (10), direct it down.
[*3]
Adjust the air conditioner compressor belt tension. For details,
see Testing and adjusting, "Testing and adjusting air conditioner
compressor belt tension".
[*4]
Tool: Torque wrench (socket)
Joint bolt for tube (24): Width across flats 19 mm, M14
3 Joint bolt for tube: 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*5], [*6]
Tool: Torque wrench (socket)
Hose clamp: Width across flats 9.5 mm (3/8 inch)
3 Hose clamp: 10.5 Nm {1.07 kgm}
[*7], [*8]
Tool: Torque wrench (socket)
Mounting bolt: Width across flats 32 mm, M22
3 Mounting bolt: 662 to 829 Nm {67.5 to 84.5 kgm}
[*9]
Tool: Torque wrench (socket)
Engine and transmission coupling bolt: Width across flats 19
mm, M12
3 Engine and transmission coupling bolt:
98 to 123 Nm {10 to 12.5 kgm}
10 WA500-6
50 Disassembly and assembly SEN02023-04
q Bleeding air
Bleed air from the brake circuit and fan drive motor circuit.
For details, see Testing and adjusting, Bleeding air from
each part.
WA500-6 11
SEN02023-04 50 Disassembly and assembly
12 WA500-6
50 Disassembly and assembly SEN02023-04
Removal
1. Drain the coolant.
6 Coolant: 90 l
2. Remove rear top hood (1).
Tool: Socket wrench
Mounting bolt for cover (1): Width across flats 19 mm, M12
3. Remove rubber cover (2) and covers (3), (4) and (5).
Tool: Socket wrench
Mounting bolt for rubber cover (2): Width across flats 17
mm, M10
Mounting bolt for rubber covers (3), (4), (5): Width across
flats 19 mm, M12
10. Remove air bleeder hose clamps (13) and right and left par-
tition plates (14).
Tool: Socket wrench
Hose (13) clamp: Width across flats 17 mm, M10
Mounting bolt for partition plate (14): Width across flats 19
mm, M12
WA500-6 13
SEN02023-04 50 Disassembly and assembly
14 WA500-6
50 Disassembly and assembly SEN02023-04
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Hose clamp: Width across flats 9.5 mm (3/8 inch)
3 Hose clamp: 10.5 Nm {1.07 kgm}
WA500-6 15
SEN02023-04 50 Disassembly and assembly
16 WA500-6
50 Disassembly and assembly SEN02023-04
Removal
1. Remove the hood. For details, see "Removal and installa-
tion of hood".
2. Remove 4 partition plates (1).
Tool: Socket wrench
Mounting bolt for partition plate (1): Width across flats
19 mm, M12
3. Loosen clamp (2) and remove hose and air intake connec-
tor (3). [*1]
Tool: Socket wrench
Clamp (2): Width across flats 9.5 mm (3/8 inch)
4. Loosen clamps (4) and (5) and remove pipe (6). [*2]
Tool: Socket wrench
Clamps (4), (5): Width across flats 9.5 mm (3/8 inch)
WA500-6 17
SEN02023-04 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Hose clamp: Width across flats 9.5 mm (3/8 inch)
3 Hose clamp: 10.5 Nm {1.07 kgm}
[*2]
Tool: Torque wrench (socket)
Hose clamp: Width across flats 9.5 mm (3/8 inch)
3 Hose clamp: 10.5 Nm {1.07 kgm}
18 WA500-6
50 Disassembly and assembly SEN02023-04
WA500-6 19
SEN02023-04 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
20 WA500-6
50 Disassembly and assembly SEN02023-04
10. Remove mounting bolt (12) and remove fan motor assem-
bly (13). [*3]
Mounting bolt (12): Width across flats 19 mm, M12
WA500-6 21
SEN02023-04 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for support: Width across flats 24 mm, M16
3 Support mounting bolt: 235 to 285 Nm {23.5 to
29.5 kgm}
[*2]
Tool: Torque wrench (socket)
Mounting nut for fan: Width across flats 30 mm, M20
3 Mounting nut for fan: 132.3 to 156.8 Nm {13.5 to
16 kgm}
a When setting the bolt holes of the nut lock plate, do not
rotate the nut in the loosening direction but rotate it in the
tightening direction.
[*3]
Tool: Torque wrench (socket)
Mounting bolt for fan motor: Width across flats 19 mm, M12
Tool: Torque wrench (socket)
Mounting bolt (14): Width across flats 24 mm, M16
3 Mounting bolt for fan motor assembly (12):
98 to 123 Nm {10 to 12.5 kgm}
a Loosen bracket mounting bolts (14) and adjust the clear-
ance between fan (11) and the shroud to more than 5.5 mm
all around the periphery.
3 Mounting bolt (14): 245 to 309 Nm {25 to 31.5 kgm}
q Bleeding air
Bleed air from the fan motor circuit. For details, see Testing
and adjusting, "Bleeding air from each part, Bleeding from
fan motor circuit".
22 WA500-6
50 Disassembly and assembly SEN02023-04
WA500-6 23
SEN02023-04 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
24 WA500-6
50 Disassembly and assembly SEN02023-04
WA500-6 25
SEN02023-04 50 Disassembly and assembly
16. Remove the 8 of radiator guard mounting bolts (18) from the
right and left.
Tool: Socket wrench
Mounting bolt (18) for radiator guard: Width across flats
30 mm, M20
17. While slinging radiator guard and cooling fan motor assem-
bly (19) slowly, move it toward the rear to remove.
Tools: 2-point chain, lever block
4 Radiator guard and cooling fan motor assembly:
320 kg
26 WA500-6
50 Disassembly and assembly SEN02023-04
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for support: Width across flats 24 mm, M16
3 Mounting bolt for support:
235 to 285 Nm {23.5 to 29.5 kgm}
[*2]
Tool: Torque wrench (socket)
Mounting bolt (17) for radiator support: Width across flats 24
mm, M16
3 Mounting bolt for radiator support:
245 to 309 Nm {25 to 31.5 kgm}
q Bleeding air
Bleed air from the fan motor circuit. For details, see Testing
and adjusting, "Bleeding air from each part, Bleeding from
fan motor circuit".
WA500-6 27
SEN02023-04 50 Disassembly and assembly
28 WA500-6
50 Disassembly and assembly SEN02023-04
Removal
k Set the lock bar to the frame, apply the parking brake, and lock the tires with chocks.
k Disconnect the cable from the negative (–) terminal of the battery.
3. Disconnect the engine oil drain valve (3) from the frame.
Tool: Socket wrench
Mounting bolt for drain valve (3): Width across flats 17 mm,
M10
4. Disconnect fuel tank breather (4) from the frame.
Tool: Socket wrench
Mounting bolt for breather (4): Width across flats 17 mm,
M10
WA500-6 29
SEN02023-04 50 Disassembly and assembly
8. Disconnect fuel return hose (8) of the fuel tank from the
tube.
Tools: Open-end wrench, special tool AB
Hose (8): Width across flats 22 mm, nominal 03
Tool: Socket wrench
Hose clamp (8): Width across flats 17 mm, M10
9. Disconnect fuel supply hose (9) of the fuel tank from the
tube and disconnect the 2 clamps.
Tools: Open-end wrench, special tool AB
Hose (9): Width across flats 22 mm, nominal 03
10. Disconnect hoses (10) between the fuel tank and water sep-
arator from the water separator and disconnect the clamp.
Tools: Open-end wrench, special tool AD
Hose (10): Width across flats 32 mm, nominal 05
Tool: Socket wrench
Hose (10) clamp: Width across flats 17 mm, M10
11. Sling fuel tank assembly (11) with the nylon sling, support its
front bottom with jack [1], and remove the 4 mounting bolts.
[*1].
Tools: Nylon sling, jack [1], socket wrench
12. While adjusting the jack height so that the bottom of fuel
tank assembly (11) will be in parallel with the ground, lower
the crane slowly.
Mounting bolt for fuel tank (11): Width across flats 36 mm,
M24
a Check that all the wiring harnesses, pipings, etc. are
disconnected.
4 Fuel tank assembly (empty): 230 kg
13. Place fuel tank assembly (11) on a palette truck [2] etc. and
pull it out of the machine.
30 WA500-6
50 Disassembly and assembly SEN02023-04
Installation
q Carry out installation in the reverse order to removal.
[*1]
a Reduce the clearance between the fuel tank and rear frame
to below 0.5 mm with shims.
Tool: Torque wrench (socket)
Mounting bolt for fuel tank: Width across flats 36 mm, M24
3 Mounting bolt for fuel tank:
785 to 980 Nm {80 to 100 kgm}
WA500-6 31
SEN02023-04 50 Disassembly and assembly
32 WA500-6
50 Disassembly and assembly SEN02023-04
Removal
1. Remove rear hood (1).
Tool: Socket wrench
Mounting bolt for hood (1): Width across flats 19 mm, M12
WA500-6 33
SEN02023-04 50 Disassembly and assembly
34 WA500-6
50 Disassembly and assembly SEN02023-04
16. Disconnect right and left gas springs (20) and rods (21).
17. Sling right and left side hood and door assemblies (22),
remove their mounting bolts, and lift them off.
Tool: Socket wrench
Mounting bolt for hood and door assembly (22): Width
across flats 19 mm, M12
4 Right and left side hood and door assemblies: 80 kg
Installation
q Carry out installation in the reverse order to removal.
WA500-6 35
SEN02023-04 50 Disassembly and assembly
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
36 WA500-6
SEN02024-05
WA500-6
WA500-6 1
SEN02024-05 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02024-05
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
WA500-6 3
SEN02024-05 50 Disassembly and assembly
7. Remove fuel tube (11) and disconnect fuel tube (12) and
fuel main filter head assembly (13). [*2]
Tool: Socket wrench
14. Remove bracket (31) and clamps (32), (33) and (34). [*6]
15. Remove 2 high-pressure pipes (35). [*7]
4 WA500-6
50 Disassembly and assembly SEN02024-05
17. Rotate the crankshaft forward and set intermediate point (a)
between stamps 2/5 TOP and 3/4 TOP on damper (37) to
pointer (38).
a At this time, check that the drive gear forcing tap is set
to the bolt hole at the top of cover (36). (If the drive
gear forcing tap is not set so, rotate the crankshaft 1
more turn.)
a At this point, the pump shaft key is at 15° to the right
from the top.
19. Install tool A1 and tighten center bolt to remove gear (39).
[*9]
a Keep tool A1 installed until the gear is installed again.
WA500-6 5
SEN02024-05 50 Disassembly and assembly
20. Remove 4 fuel supply pump mounting bolts (40) and fuel
supply pump assembly (41).
6 WA500-6
50 Disassembly and assembly SEN02024-05
Installation
q Carry out installation in the reverse order to removal.
[*1]
Adjust the air conditioner compressor belt tension. For details,
see Testing and adjusting, "Testing and adjusting air conditioner
compressor belt tension".
[*2]
3 Joint bolt for fuel tubes (11) and (12):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
(Supply pump side)
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
(Filter side)
[*3]
3 Joint bolt for fuel supply hose (15):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*4]
3 Sleeve nut for oil tube (22): 43 to 47 Nm {4.4 to 4.8 kgm}
[*5]
3 Joint bolt for fuel tubes (25) and (26):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
[*6], [*7]
1) Finger tighten tube (35) first and then tighten it perma-
nently.
3 High-pressure pipe sleeve nut:
39.2 to 49.0 Nm {4.0 to 5.0 kgm}
(Supply pump side)
39.2 to 58.8 Nm {4.0 to 6.0 kgm}
(Common rail side)
2) Finger tighten tube clamps (32), (33) and (34) first and
then tighten them permanently.
3 Mounting bolt for tube clamp:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
3) Direct the notch of the scatter prevention cover on the
supply pump side toward the block and direct that on
the common rail side down.
[*8], [*9]
1) Remove the center screw for tool A1. Leave tool A1
installed to the gear, set the key of fuel supply pump
(41) up, and insert the supply pump along the gear
groove.
2) Tighten fuel supply pump assembly mounting bolts
(40).
2 Mounting bolt for supply pump: Adhesive (LT-2)
3) Remove tool A1.
WA500-6 7
SEN02024-05 50 Disassembly and assembly
q Bleeding air
Bleed air from the fuel circuit. For details, see Testing and
adjusting, "Bleeding air from fuel circuit".
8 WA500-6
50 Disassembly and assembly SEN02024-05
WA500-6 9
SEN02024-05 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
6. Loosen hose clamps (11) between the air cleaner and tur-
bocharger and remove air cleaner fixing bands (12) and air
cleaner assembly (13). [*2]
7. Remove the muffler fixing band and 4 mounting bolts and lift
off muffler assembly (14).
4 Muffler assembly: 50 kg
10 WA500-6
50 Disassembly and assembly SEN02024-05
WA500-6 11
SEN02024-05 50 Disassembly and assembly
15. Disconnect fuel tube (28) and remove fuel filter and bracket
assembly (29). [*3]
16. Disconnect 2 tubes (30) and remove corrosion resistor and
bracket assembly (31).
17. Remove oil tubes (32) and oil filter and bracket assembly
(33).
a Make match marks on these tubes since their tops, bot-
toms, inlets and outlet are mistakable.
18. Disconnect fuel return tube (34). [*4]
22. Remove air connector (38) and electrical intake air heater.
23. Remove bracket (39), clamps (40) and EGR tubes (41) and
(42). [*5]
24. Remove clamps (43), (44), (45), (46) and (47) and brackets
(48), (49), (50), (51) and (52).
12 WA500-6
50 Disassembly and assembly SEN02024-05
WA500-6 13
SEN02024-05 50 Disassembly and assembly
31. Lift off air intake connector assembly (60) and joint housing
together.
4 Air intake connector assembly: 35 kg
32. Disconnect connectors TIM (61), PIM (62) and TFUEL (63).
14 WA500-6
50 Disassembly and assembly SEN02024-05
39. Sling air intake manifold assembly (74), remove its mount-
ing bolts, and lift it off. [*12]
a The 2 high-pressure pipe brackets are mounted
together.
4 Air intake manifold assembly: 50 kg
43. Remove bracket (81) and EGR cooler inlet tube (82). [*14]
WA500-6 15
SEN02024-05 50 Disassembly and assembly
16 WA500-6
50 Disassembly and assembly SEN02024-05
49. Remove the 3 mounting bolts and rocker arm and shaft
assembly (88). [*19]
a Loosen locknut (89), and then loosen adjustment screw
(90) fully so that an excessive force will not be applied
to the push rod when the rocker arm is installed.
52. Remove 2 nuts (93) from the solenoid valve of the fuel injec-
tor. [*22]
a Loosen the nuts alternately.
53. Pull out spring clamp (94).
54. Disconnect clamp (95).
55. Remove the fixing bolt and holder of connector (96), push in
the connector, and remove the injector wiring harness. [*23]
56. Loosen mounting bolt (98) of holder (97). [*24]
57. Insert a small L-bar under the connector of the fuel injector
and pry out fuel injector assembly (99) slowly. [*25]
a Do not grip the solenoid valve at the top of the injector
with pliers etc. to pull off the injector.
WA500-6 17
SEN02024-05 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
3 Tube hose clamp: 10.5 Nm {1.07 kgm}
a When installing the clamp, direct it down.
[*2]
3 Air cleaner hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
3 Tube joint bolt: 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*4]
3 Tube joint bolt: 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*5]
3 Tube joint bolt: 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*6], [*7]
3 Mounting bolt for EGR valve: 59 to 74 Nm {6 to 7.5 kgm}
[*8]
3 Mounting bolt for bracket: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*9]
3 Mounting bolt for high-pressure pipe clamp:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*10]
3 Spill pipe joint bolt: 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*11]
3 Lubrication tube joint bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*12]
a Install the gasket with the "UP" mark up.
a Tighten the air intake manifold assembly mounting bolts in
the order of [1] – [24] as shown in the figure.
3 Mounting bolt for air intake manifold:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
[*13]
3 Connector hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
18 WA500-6
50 Disassembly and assembly SEN02024-05
[*14]
3 Mounting bolt fro EGR cooler:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
[*15]
Apply heat-resistant sealant to the fitting parts of the exhaust
manifold (between ports No. 2 and No. 3 and between ports No.
4 and No. 5).
2 Fitting parts: Heat-resistant sealant (HOLTZ MH705)
a Tighten the 3 bolts of [1] – [3] shown below temporarily in
the numeric order and then tighten other bolts [4] – [24]
temporarily in the numeric order. Then, tighten all bolts [1] –
[24] to the specified torque in the numeric order.
2 Threads of mounting bolt: Anti-seizure compound (LC-G)
3 Mounting bolt for exhaust manifold:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
[*16]
3 Air bleeding tube joint bolt:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*17]
k Before installing the high-pressure pipe, check it for the
following defects. If there is any of these defects, it can
cause fuel leakage. Accordingly, replace the high-pres-
sure pipe.
q Check the taper seal of the connecting part (Part (a): Part of
2 mm from the end) for visible lengthwise slit (b) and dent
(c).
q Check part (d) (End of the taper seal: Part at 2 mm from the
end) for stepped-type wear (fatigue) which your nail can
feel.
[*18]
3 Mounting bolt for head cover:
29.4 to 34.3 Nm {3.0 to 3.5 kgm}
a Tighten the bolts temporarily which are also used to fix the
wiring harness clamp.
WA500-6 19
SEN02024-05 50 Disassembly and assembly
[*19]
a Before tightening the mounting bolts, check that the adjust-
ment screw ball is fitted in the push rod socket.
3 Mounting bolt for rocker arm and shaft assembly:
93 to 103 Nm {9.5 to 10.5 kgm}
a For adjustment of the valve clearance, see Testing and
adjusting, "Adjusting valve clearance".
[*20]
a Check that the push rod is in the cam follower.
[*21]
a Adjust the crosshead according to the following procedure.
1) Loosen the locknut and return the adjustment screw.
2) While holding the crosshead top lightly, tighten the
adjustment screw.
3) After the adjustment screw touches the valve stem,
tighten it 20° more.
4) Tighten the locknut.
3 Locknut: 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
[*22]
a Eliminate the slack of the injector wiring harness and press
it against the injector body so that it will not interfere with the
rocker arm.
a Tighten the nuts alternately.
3 Wiring harness terminal nut:
2.0 ± 0.2 Nm {0.2 ± 0.02 kgm}
[*23]
a Since the injector wiring harness fitted with the O-ring is dif-
ficult to insert from inside, install it according to the following
procedure.
1) Remove O-ring (102) from connector (96) and pass the
wiring harness out from inside of the cylinder head and
then fit the O-ring.
2 O-ring: Engine oil (EO30)
2) Install holder (103) to connector (96) and push the con-
nector into the position where the O-ring is fitted.
3) Fix the holder with mounting bolt (104).
20 WA500-6
50 Disassembly and assembly SEN02024-05
[*24], [*25]
a Install the injector assembly according to the following pro-
cedure.
1) Check that there is not dirt in the injector sleeve.
2) Install gasket (105) and O-ring (106) to fuel injector
(99).
2 O-ring: Engine oil
3) Insert holder (97) in the fuel injector and insert the
injector connector, directing it toward the high-pressure
pipe insertion hole.
4) Install the spherical washer to bolt (98) and tighten
holder (97) temporarily.
2 Spherical washer: Engine oil
5) Insert high-pressure pipe sleeve (107) through the
high-pressure pipe insertion part, setting it to injector
connector (108), and tighten it temporarily.
a Tighten the sleeve nut on the common rail side,
too, and take care that the high-pressure pipe will
not slant.
6) Tighten holder (97) permanently.
a While pulling the high-pressure pipe in the oppo-
site direction to the injector, tighten the bolt.
3 Mounting bolt for holder:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening the holder, remove the high-pres-
sure pipe.
[*26]
a Check the cylinder head mounting bolts for the following
items. If they are out of the standard, do not use them but
replace them.
q Number of tightening times must be 5 or less (Number of
punch marks denoting the number of tightening times must
be 5 or less).
q Using limit length of bolt stem (e)
Short bolt: Max. 170.8 mm
Long bolt: Max. 205.8 mm
WA500-6 21
SEN02024-05 50 Disassembly and assembly
a When not using tool A2, make marks (a) and (b) on each
bolt and cylinder head with paint, and then tighten the bolts
by 90° (+30°/0)
a After tightening bolts 1 – 6, tighten bolt 7.
3 Bolt 7: 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
[*27]
a Check that there is not dirt or foreign matter on the cylinder
head mounting face and in the cylinder, and then set the
gasket to the cylinder head.
a When fitting the gasket, check that the grommets are fitted
correctly.
q Bleeding air
Bleed air from the fuel system. For details, see Testing and
adjusting, "Bleeding air from fuel system".
22 WA500-6
50 Disassembly and assembly SEN02024-05
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
3. Loosen hose clamps (2) between the air cleaner and turbo-
charger and remove the air cleaner fixing band and air
cleaner assembly (3). [*1]
WA500-6 23
SEN02024-05 50 Disassembly and assembly
11. Remove the 3 mounting bolts and rocker arm and shaft
assembly (13). [*4]
a Loosen the locknut (14), and then loosen the adjust-
ment screw (15) fully so that an excessive force will not
be applied to the push rod when the rocker arm is
installed.
12. Remove 2 nuts (16) from the solenoid valve of the fuel injec-
tor. [*5]
a Loosen nuts (16) alternately.
13. Remove wiring harness clamp (17).
14. Remove the mounting bolts (19) of holder (18) and then
remove fuel injector (20) and holder (18) together.[*6]
a Insert a small L-bar under the connector of the fuel
injector and pry out the fuel injector assembly (20)
slowly.
a Do not grip the solenoid valve at the top of the injector
with pliers etc. to pull off the injector.
24 WA500-6
50 Disassembly and assembly SEN02024-05
Installation
q Carry out installation in the reverse order to removal.
[*1]
3 Air cleaner hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
k Before installing the high-pressure pipe, check it for the
following defects. If there is any of these defects, it can
cause fuel leakage. Accordingly, replace the high-pres-
sure pipe.
q Check the taper seal of the connecting part (Part (a): Part of
2 mm from the end) for visible lengthwise slit (b) and dent
(c).
q Check part (d) (End of the taper seal: Part at 2 mm from the
end) for stepped-type wear (fatigue) which your nail can
feel.
2 High-pressure pipe sleeve O-ring: Engine oil (EO30-DH)
3 High-pressure pipe sleeve nut:
39.2 to 49 Nm {4 to 5 kgm}
3 Mounting bolt for high-pressure pipe clamp:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*3]
3 Mounting bolt for cylinder head cover:
29.4 to 34.3 Nm {3.0 to 3.5 kgm}
[*4]
a Before tightening the mounting bolts, check that the adjust-
ment screw ball is fitted in the push rod socket.
3 Mounting bolt for rocker arm:
93 to 103 Nm {9.5 to 10.5 kgm}
q For adjustment of the valve clearance, see Testing and
adjusting, "Adjusting valve clearance".
[*5]
a Take up the slack of the wiring harness and press it against
injector.
a Tighten the nuts alternately.
3 Terminal nut: 2.0 ± 0.2 Nm {0.2 ± 0.02 kgm}
WA500-6 25
SEN02024-05 50 Disassembly and assembly
[*6]
a Install the injector assembly according to the following pro-
cedure.
1) Check that there is not dirt in the injector sleeve.
2) Install gasket (21) and O-ring (22) to fuel injector (20).
2 O-ring: Engine oil
3) Insert holder (18) in the fuel injector and insert the
injector connector (24), directing it toward the high-
pressure pipe insertion hole.
4) Install the spherical washer to bolt (19) and tighten
holder (18) temporarily.
2 Spherical washer: Engine oil
5) Insert high-pressure pipe sleeve (23) through the high-
pressure pipe insertion part, setting it to injector con-
nector (24), and tighten it temporarily.
a Tighten the sleeve nut on the common rail side,
too, and take care that the high-pressure pipe will
not slant.
6) Tighten holder (18) permanently.
a While pulling the high-pressure pipe in the oppo-
site direction to the injector, tighten the bolt.
3 Mounting bolt for holder:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening the holder, remove the high-pres-
sure pipe.
26 WA500-6
50 Disassembly and assembly SEN02024-05
WA500-6 27
SEN02024-05 50 Disassembly and assembly
Removal
1. Remove right and left partition covers (1) and cover mount-
ing supports.
Tool: Socket wrench
Mounting bolt for rubber cover (1): Width across flats 19
mm, M12
Mounting bolt for support: Width across flats 14 mm, M10
Mounting bolt for support: Width across flats 19 mm, M12
28 WA500-6
50 Disassembly and assembly SEN02024-05
Installation
a Check the seal by checking the wear of the shaft and Standard spare seal Sleeved seal
replace it with the "standard seal" or "sleeved seal".
If the shaft is worn to the degree of luster (If wear which you
feel with your finger is less than 10 mm) and does not have
any flaw, install "standard seal A". In other cases, install
"sleeved seal B".
a (7): Plastic inside cylinder which is also used as installation
guide.
a (6): Sleeve.
a Do not remove installation guide (7) from front seal (3)
before installing the front seal.
a Handle front seal (3) and sleeve (6) as an assembly and
never separate them from each other.
2) Push the metal ring of front seal (3) evenly as if you are
passing over the large inside diameter side of plastic
inside cylinder (7).
a Hit the metal ring of front seal with plastic hammer
evenly.
a Do not hit it strongly.
3) After pushing in the seal, remove plastic inside cylinder
(7).
a When removing the inside cylinder, take care not
to damage the seal lip.
WA500-6 29
SEN02024-05 50 Disassembly and assembly
4) Using tool A4, tighten the 3 bolts evenly to press fit seal
(3) until the end of tool A4 reaches the end of crank-
shaft (5).
a Tighten tool A4 first until the 55-mm bolts stop and
then replace the 55-mm bolts with the 35-mm bolts
and tighten them.
a Seal driving distance (a) from crankshaft:
9.1 – 10.1 mm
a When press fitting the seal, take care not to dam-
age the lip of the seal with the tool set etc.
a After press fitting the seal, remove the red sealant
layer from its periphery.
2. Procedure for installing sleeved seal
a When installing the front seal, do not apply oil or grease
to the shaft, inside cylinder surface of sleeve (6) and
seal lip.
1) Set seal (3) to tool A5.
2 Sleeve (6) inside cylinder surface:
Gasket sealant (LG-7)
30 WA500-6
50 Disassembly and assembly SEN02024-05
WA500-6 31
SEN02024-05 50 Disassembly and assembly
Removal
1. Remove the engine assembly. For details, see "Removal
and installation of engine assembly".
2. Remove ring gear (1).
3. Install eyebolt [1] to flywheel (2) and sling it. Remove bolts
(3) and flywheel (2).
4. While moving flywheel (2) toward this side and lift it off.
k Since the socket part of the flywheel is shallow, it
may fall suddenly. Take care not to catch your fin-
gers in the flywheel.
4 Flywheel: 60 kg
32 WA500-6
50 Disassembly and assembly SEN02024-05
(Tool A3)
WA500-6 33
SEN02024-05 50 Disassembly and assembly
Installation
a Check the Teflon seal (Laydown lip seal) by checking the
wear of the shaft and replace it with the "standard seal" or
"sleeved seal".
If the shaft is worn to the degree of luster (If wear which you
feel with your finger is less than 10 mm) and does not have
any flaw, install "standard seal A". In other cases, install
"sleeved seal B".
a (8): Plastic inside cylinder which is also used as instal- (Left: Standard seal, Right: Sleeved seal)
lation guide.
a (6): Sleeve.
a Do not remove plastic inside cylinder (8) from rear seal
(4) before installing the rear seal.
a Handle rear seal (4) and sleeve (7) as an assembly and
never separate them from each other.
34 WA500-6
50 Disassembly and assembly SEN02024-05
4) Tighten the 4 bolts evenly to press fit rear seal (4) until
the end of tool A6 (for press fitting the seal) reaches
the end of crankshaft (6).
a Tighten tool A6 (for press fitting the seal) first until
the bolt without washer stops and then tighten the
bolt with 2 washers.
a When press fitting the seal, take care not to dam-
age the lip with the tool set etc.
a After press fitting the seal, remove the red sealant
layer from its periphery.
3. Flywheel
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (2),
install it to the crankshaft, and tighten bolts (3).
a If there are 5 punch marks on a bolt, do not use that
bolt but replace it.
2 Threads and seat of bolt: Engine oil (EO30)
WA500-6 35
SEN02024-05 50 Disassembly and assembly
36 WA500-6
50 Disassembly and assembly SEN02024-05
WA500-6 37
SEN02024-05 50 Disassembly and assembly
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
38 WA500-6
SEN02025-06
WA500-6
WA500-6 1
SEN02025-06 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 3
SEN02025-06 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
k Release residual pressure in brake accumulator circuit. For detail, see Testing and adjusting
"Releasing residual pressure in brake accumulator circuit".
11. Support rear drive shaft (5) with transmission jack [1],
remove its mounting bolts (6), and lift it off. [*2]
Tools: Mission jack [1], socket wrench
Mounting bolt (6) for rear drive shaft: Width across flats 19
mm, M12
a Before removing the drive shaft, make a match mark on
the coupling.
4 Rear drive shaft: 45 kg
4 WA500-6
50 Disassembly and assembly SEN02025-06
12. Remove bracket (7) and transmission oil feed tube (8).
Tool: Socket wrench
Mounting bolt for bracket (7): Width across flats 19 mm,
M12
Mounting bolt for oil feed tube (8): Width across flats 19
mm, M12
13. Disconnect hoses (9) and (10) at transmission oil filter side.
Tools: Open-end wrench, special tools AB, AA
Hose (9): Width across flats 22 mm, nominal 03
Hose (10): Width across flats 19 mm, nominal 02
Tool: Socket wrench
Hoses (9), (10) clamp: Width across flats 17 mm, M10
a Disconnect two clamps, too.
14. Disconnect hose (11).
Tools: Socket wrench
Hose (11): Width across flats 14 mm, M10
15. Disconnect parking brake hose (12).
Tools: Open-end wrench, special tool AA
Hose (12): Width across flats 22 mm, nominal 03
WA500-6 5
SEN02025-06 50 Disassembly and assembly
20. Loosen hose clamp (19) and remove U-bolt (20) and trans-
mission suction tube (21).
Tool: Socket wrench
Hose clamp (19): Width across flats 9.5 mm (3/8 inch)
U-bolt (20): Width across flats 17 mm, M10
6 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 7
SEN02025-06 50 Disassembly and assembly
38. Remove U-bolt (50) and disconnect oil cooler tube (51).
Tool: Socket wrench
U-bolt (50): Width across flats 14 mm, M10
4 mounting bolts (rear side) for oil cooler tube (51): Width
across flats 14 mm, M10
2 mounting bolts (front side) for oil cooler tube (51): Width
across flats 19 mm, M12
40. Remove connecting bolts (54) of the engine and torque con-
verter and transmission assembly. [*4]
Tool: Socket wrench
Engine and torque converter, transmission coupling
bolt (54): Width across flats 19 mm, M12
8 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 9
SEN02025-06 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for center drive shaft: Width across flats 19 mm,
M12
3 Center drive shaft mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*2]
Tool: Torque wrench (socket)
Mounting bolt for rear drive shaft: Width across flats 19 mm, M12
3 Rear drive shaft mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
a Tighten the drive shaft according to the following procedure.
1) Check that the seats of the mating yoke and drive shaft
spider are free from rust, foreign matter (masking mate-
rial), bruise, etc.
2) Set the key way of the yoke vertically, place the drive
shaft on the bottom of the yoke socket, and fit the key
in the key way.
3) Insert the 4 upper and lower bolts and finger tighten
them until the seats of the spider and yoke are fitted.
a At this time, if the key way and socket of the yoke
are tight and the spider is not fitted easily, drive in
the spider with a plastic hammer (or a copper ham-
mer). (Do not use a steel hammer which can dam-
age the cross bearing.)
a If the spider is not fitted perfectly at this time, it will
float and its seat will be parted from the yoke when
the other parts are tightened. Accordingly, tighten
the spider securely.
4) Basically, tighten the bolts in the diagonal order.
[*3]
Tool: Torque wrench (socket)
Mounting bolt for bracket (53): Width across flats 24 mm, M16
3 Bracket (53) mounting bolt:
235 to 285 Nm {23.5 to 29.5 kgm}
3 Transmission mounting bolt:
662 to 829 Nm {67.5 to 84.5 kgm}
a Adjust the clearance between bracket (53) and lock adjust-
ment bolt (52) to 1.0 – 1.5 mm and then tighten the locknut.
2 Threaded part of lock adjustment bolt: Adhesive (LT-2)
[*4]
Tool: Torque wrench (socket)
Engine and torque converter, transmission coupling bolt: Width
across flats 19 mm, M12
3 Connecting bolt of engine and torque converter and
transmission assembly: 98 to 123 Nm {10– 12.5 kgm}
10 WA500-6
50 Disassembly and assembly SEN02025-06
Add oil through the oil filler to the specified level. Run the
engine to circulate the oil through the system. Then, check
the oil level again.
q Bleeding air
q Bleed air from the brake circuits. For details, see Test-
ing and adjusting, "Bleeding air from brake circuit".
q Bleed air from the related circuit. For details, see Test-
ing and adjusting, "Bleeding air from work equipment
circuit".
WA500-6 11
SEN02025-06 50 Disassembly and assembly
12 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 13
SEN02025-06 50 Disassembly and assembly
Preparation work
1. Set torque converter and transmission assembly (1).
Tool: 2-point chain
4 Torque converter and transmission assembly:
1,700 kg (Lockup specification)
1,650 kg (Lockup-less specification)
The 3 bolts marked with * are used to clamp other parts, too.
(Lockup specification)
14 WA500-6
50 Disassembly and assembly SEN02025-06
(Lockup-less specification)
7. Remove pipes (14) and (15), block (16) and heater plug
(17).
Tool: Socket wrench
Mounting bolt for tube (14): Width across flats 17 mm, M10
Tools: Open-end wrench, special tool AA
Tube (15): Width across flats 19 mm, nominal 02
Tool: Socket wrench
Mounting bolt for block (16): Width across flats 17 mm, M10
Heater plug (17): Width across flats 17 mm, M10
WA500-6 15
SEN02025-06 50 Disassembly and assembly
Disconnection
1. Set torque converter and transmission assembly (1).
Tools: 4-point chain, eyebolts (M24 3), (M16 2)
4 Torque converter and transmission assembly:
1,700 kg (Lockup specification)
1,650 kg (Lockup-less specification)
3. Input transfer
1) Remove 16 mounting bolts (4). [*4]
Tool: Socket wrench
Mounting bolt (4): Width across flats 19 mm, M12
2) Lift off input transfer (5).
Tools: 2-point chain, eyebolt (M19)
4 Input transfer: 140 kg
4. Transmission assembly
1) Remove 4 lower mounting bolts (6a) and 8 upper
mounting bolts (6b), and remove the case using bolts.
[*5]
Tool: Socket wrench
Mounting bolts (6a), (6b): Width across flats 19 mm,
M12
2) Sling transmission assembly (7) and lift it off from trans-
fer assembly (8).
Tools: 2-point chain, eyebolt (M12 1.75)
4 Transmission assembly: 550 kg
4 Transfer assembly: 440 kg
16 WA500-6
50 Disassembly and assembly SEN02025-06
Connection
q Carry out connection in the reverse order to disconnection.
q Before fitting the O-ring, apply grease (G2-LI) to it.
[*1]
Install the transmission control valve by using guide bolts [1].
The 3 bolts marked with * are used to clamp other parts, too.
(Lockup specification)
(Lockup-less specification)
[*2]
Lightly tighten all of the joint bolts in the order of A, B, C, D, and
E (5 places), then tighten them to the torque shown below.
Tool: Torque wrench (socket)
Joint bolt (2a): Width across flats 19 mm, M14
3 Joint bolt A: 34.3 to 44.1 Nm {3.5 to 4.5 kgm}
Tool: Torque wrench (socket)
Joint bolt (2b): Width across flats 22 mm, M16
3 Joint bolt B, C: 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
Tool: Torque wrench (socket)
Joint bolt (2c): Width across flats 17 mm, M12
3 Joint bolt D, E: 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
WA500-6 17
SEN02025-06 50 Disassembly and assembly
[*3]
(Only lockup specification)
2 Input shaft seal ring: Grease (G2-LI)
a Project the seal ring evenly from the shaft.
a If the seal ring is pushed forcibly, it may be broken. Take
care.
Tool: Torque wrench (socket)
Mounting bolt (2a), (2b) for torque converter: Width across flats
19 mm, M12
3 Torque converter mounting bolts (2a), (2b):
98 to 122.5 Nm {10 to 12.5 kgm}
[*4]
Tool: Torque wrench (socket)
Mounting bolt (4) for input transfer: Width across flats 19 mm,
M12
3 Input transfer mounting bolt (4):
98 to 122.5 Nm {10 to 12.5 kgm}
[*5]
Tool: Torque wrench (socket)
Mounting bolt (6a), (6b) for transmission: Width across flats 19
mm, M12
3 Transmission mounting bolts (6a), (6b):
98 to 122.5 Nm {10 to 12.5 kgm}
2 Transmission shaft (Spline): Grease (LM-G)
18 WA500-6
50 Disassembly and assembly SEN02025-06
Disassembly
1. Disconnect the input transfer assembly from the power train
unit. For details, see "Disconnection and connection of
power train unit".
2. Input shaft
1) Remove input shaft speed sensor (1) and input shaft
(2).
Tool: Open-end wrench
Speed sensor (1): Width across flats 24 mm
Lock nut for speed sensor (1): Width across flats
27 mm
q Lockup-less specification
WA500-6 19
SEN02025-06 50 Disassembly and assembly
20 WA500-6
50 Disassembly and assembly SEN02025-06
8. Outer race
Using puller [4], remove outer race (20) from the case.
Tool: Puller [4]
WA500-6 21
SEN02025-06 50 Disassembly and assembly
Assembly
1. Outer race (Driven gear side)
Using push tool [1] (outer diameter: 124 mm), press fit outer
race (20) to the case.
Tool: Push tool [1]
22 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 23
SEN02025-06 50 Disassembly and assembly
24 WA500-6
50 Disassembly and assembly SEN02025-06
7. Input shaft
1) Install seal ring (3) to input shaft (2).
2 Seal ring: Grease (G2-LI)
2 Input shaft (Spline): Grease (LM-G)
q Lockup specification
WA500-6 25
SEN02025-06 50 Disassembly and assembly
q Lockup-less specification
26 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 27
SEN02025-06 50 Disassembly and assembly
28 WA500-6
50 Disassembly and assembly SEN02025-06
Disassembly
1. Disconnect the torque converter assembly from the power
train unit. For details, see "Disconnection and connection of
power train unit".
2. Torque converter assembly
1) Set torque converter assembly (1) on the block.
Tools: Block, 3-point chain
2) Remove 12 mounting bolts (2).
Tool: Torque wrench
Mounting Bolt (2): Width across flats 19 mm, M12
3. Housing
1) Using eyebolts [1], sling housing (3).
Tools: Sling bolt [1], 2-point chain
2) Using forcing screws [2], remove housing (3).
Tool: Forcing screw [2]
4. Pilot
1) Remove 8 mounting bolts (4).
Tool: Socket wrench
Mounting bolt (4): Width across flats 19 mm, M12
2) Using forcing screws [3], remove pilot (65).
Tool: Forcing screw [3]
WA500-6 29
SEN02025-06 50 Disassembly and assembly
30 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 31
SEN02025-06 50 Disassembly and assembly
32 WA500-6
50 Disassembly and assembly SEN02025-06
8) Remove inner race (34) and seal ring (35) from stator
shaft (29).
7) Remove snap ring (42) and outer race (43) on the case
side.
Tool: Snap ring pliers
WA500-6 33
SEN02025-06 50 Disassembly and assembly
7) Remove snap ring (50) and outer race (51) on the case
side.
Tools: Snap ring pliers, steel bar, hammer
34 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 35
SEN02025-06 50 Disassembly and assembly
Assembly
1. Idler gear
1) Install bearings (54a) and (54b) to gear (53).
4) Using push tool [4] (outer diameter: 124 mm), press fit
bearing (58) to the cover.
Tool: Push tool [4] (outer diameter 124 mm)
5) Install snap ring (46b).
Tool: Snap ring pliers
36 WA500-6
50 Disassembly and assembly SEN02025-06
4) Using push tool [8] (outer diameter: 149 mm), press fit
bearing (57) to the cover.
Tool: Push tool [8] (outer diameter 149 mm)
5) Install snap ring (38b).
Tool: Snap ring pliers
WA500-6 37
SEN02025-06 50 Disassembly and assembly
*
38 WA500-6
50 Disassembly and assembly SEN02025-06
6) Using push tool [12] (inner diameter: 121 mm), press fit
inner race (66) to stator shaft (29).
Tool: Push tool [12] (inner diameter 121 mm)
8) Install the bolts to the pump case and lock them with
bar [8].
Tool: Bar [8]
9) Using tool F2, tighten nut (26).
2 Mounting bolt: Adhesive (LT-2)
Tool: Special tool F2
3 Mounting bolt: 441 to 490 Nm {45 to 50 kgm}
a After tightening nut (26), drop 6 cc of TO30 or
TO10 onto the bearing and rotate the bearing 10
turns. Then, check the tightening torque again.
3 Mounting bolt: 441 to 490 Nm {45 to 50 kgm}
WA500-6 39
SEN02025-06 50 Disassembly and assembly
5. Stator assembly
1) Install freewheel (24) to race (23).
a When inserting freewheel (24), do not use a ham-
mer etc. but use your hands.
a When inserting the freewheel, take care of ball
(25).
6. Turbine assembly
1) Install snap ring (12).
Tool: Snap ring pliers
2) Install turbine (14) to the turbine boss and tighten 20
mounting bolts (13).
Tool: Torque wrench (socket)
Mounting bolt (13): Width across flats 17 mm, M10
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 59 to 74 Nm {6 to 7.5 kgm}
40 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 41
SEN02025-06 50 Disassembly and assembly
5) Using push tool [16] (outer diameter: 179 mm), press fit
bearing (18).
Tools: Push tool [16] (outer diameter 179 mm), plastic
hammer
11. Pilot
Install pilot (65) and tighten 8 mounting bolts (4).
2 Mounting bolt: Adhesive (LT-2)
Tool: Torque wrench (socket)
Mounting bolt (4): Width across flats 19 mm, M12
3 Mounting bolt: 98 to 122.5 Nm {10 to 12.5 kgm}
42 WA500-6
50 Disassembly and assembly SEN02025-06
13. Housing
1) Fit the O-ring and install housing (3), using eyebolts
[19].
Tools: Sling bolt [19], 2-point chain
2) Tighten 12 mounting bolts (2).
Tool: Torque wrench (socket)
Mounting Bolt (2): Width across flats 19 mm, M12
2 O-ring: Grease (G2-LI)
3 Mounting bolt: 98 to 122.5 Nm {10 to 12.5 kgm}
14. Connect the torque converter assembly to the power train
unit. For details, see "Disconnection and connection of
power train unit".
WA500-6 43
SEN02025-06 50 Disassembly and assembly
44 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 45
SEN02025-06 50 Disassembly and assembly
Disassembly
1. Disconnect the torque converter assembly from the power
train unit. For details, see "Disconnection and connection of
power train unit".
2. Housing
1) Set torque converter assembly (1) on the block.
Tools: Block, 3-point chain
2) Remove 12 mounting bolts (2).
Tool: Socket wrench
Mounting Bolt (2): Width across flats 19 mm, M12
3) Remove housing (3).
3. Pilot
1) Remove 8 mounting bolts (4).
Tool: Torque wrench
Mounting bolt (4): Width across flats 19 mm, M12
2) Remove pilot (5).
46 WA500-6
50 Disassembly and assembly SEN02025-06
9. Stator
1) Remove snap ring (18).
Tool: Snap ring pliers
2) Remove stator (19).
Tool: Socket wrench
WA500-6 47
SEN02025-06 50 Disassembly and assembly
48 WA500-6
50 Disassembly and assembly SEN02025-06
8) Remove inner race (28) and seal ring (29) from stator
shaft (23).
9) Remove collar (52).
7) Remove snap ring (37) and outer race (38) on the case
side.
Tool: Snap ring pliers
WA500-6 49
SEN02025-06 50 Disassembly and assembly
7) Remove snap ring (46) and outer race (47) on the case
side.
Tools: Snap ring pliers, steel bar, hammer
50 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 51
SEN02025-06 50 Disassembly and assembly
Assembly
1. Idler gear
1) Install bearings (50a) and (50b) to gear (49).
4) Using push tool [3] (outer diameter: 124 mm), press fit
bearing (45) to the cover.
Tool: Push tool [3] (outer diameter 124 mm)
5) Install snap ring (41b).
Tool: Snap ring pliers
52 WA500-6
50 Disassembly and assembly SEN02025-06
4) Using push tool [8] (outer diameter: 149 mm), press fit
bearing (36) to the cover.
Tool: Push tool [8] (outer diameter 149 mm)
5) Install snap ring (32b).
Tool: Snap ring pliers
WA500-6 53
SEN02025-06 50 Disassembly and assembly
3) Using push tool [12] (inner diameter: 121 mm), press fit
inner race (28) to stator shaft (23).
Tool: Push tool [12] (inner diameter 121 mm)
4) Install seal ring (29).
2 Seal ring: Grease (G2-LI)
>@
*
54 WA500-6
50 Disassembly and assembly SEN02025-06
7) Using push tool [12] (inner diameter: 121 mm), press fit
inner race (55) to stator shaft (23).
Tool: Push tool [12] (inner diameter 121 mm)
9) Install the bolts to the pump case and lock them with
bar [2].
Tool: Bar [2]
10) Using tool F2, tighten nut (20).
2 Mounting bolt: Adhesive (LT-2)
Tool: Special tool F2
3 Mounting bolt: 441 to 490 Nm {45 to 50 kgm}
a After tightening nut (20), drop 6 cc of TO30 or
TO10 onto the bearing and rotate the bearing 10
turns. Then, check the tightening torque again.
3 Mounting bolt: 441 to 490 Nm {45 to 50 kgm}
5. Stator
1) Install stator (19).
2) Install snap ring (18).
Tool: Snap ring pliers
WA500-6 55
SEN02025-06 50 Disassembly and assembly
6. Turbine assembly
1) Install snap ring (14).
Tool: Snap ring pliers
2) Install turbine (16) to the turbine boss and tighten 20
mounting bolts (15).
2 Mounting bolt: Adhesive (LT-2)
Tool: Torque wrench (socket)
Mounting bolt (15): Width across flats 17 mm, M10
3 Mounting bolt: 59 to 74 Nm {6 to 7.5 kgm}
2) Using push tool [13] (outer diameter: 179 mm), press fit
bearing (17) to drive case (63).
Tool: Push tool [13] (outer diameter 179 mm)
56 WA500-6
50 Disassembly and assembly SEN02025-06
9. Turbine assembly
1) Sling and install turbine assembly (10).
Tools: Sling bolt, 2-point chain
2) Tighten 36 lower mounting bolts (9).
2 Mounting bolt: Adhesive (LT-2)
Tool: Torque wrench (socket)
Mounting bolt (9): Width across flats 17 mm, M10
3 Mounting bolt: 49 to 58.8 Nm {5 to 6 kgm}
Tool: Torque wrench (socket)
Drain plug: Width across flats 17 mm, M10
3 Drain plug (2 pieces):
9.8 to 12.7 Nm {1 to 1.3 kgm}
10. Pilot
Install pilot (5) and tighten 8 mounting bolts (4).
2 Mounting bolt: Adhesive (LT-2)
Tool: Torque wrench (socket)
Mounting bolt (4): Width across flats 19 mm, M12
3 Mounting bolt: 98 to 122.5 Nm {10 to 12.5 kgm}
WA500-6 57
SEN02025-06 50 Disassembly and assembly
12. Housing
1) Fit the O-ring to housing (3).
Tools: Sling bolt, 2-point chain
2) Sling housing (3) and install it to torque converter
assembly (1).
Tool: Torque wrench (socket)
Mounting bolt (2): Width across flats 19 mm, M12
3) Tighten 12 mounting bolts (2).
2 O-ring: Grease (G2-LI)
3 Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}
58 WA500-6
50 Disassembly and assembly SEN02025-06
WA500-6 59
SEN02025-06
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 10-20 (01)
60
SEN02026-06
WA500-6
WA500-6 1
SEN02026-06 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 3
SEN02026-06 50 Disassembly and assembly
Disassembly
1. Disconnect the transmission assembly from the power train
unit. For details, see “Uncoupling and coupling of power
train unit”.
2. Sleeves
Using forcing screw [1], remove 5 sleeves (1).
Tools: Forcing screw [1]
3. Transmission assembly
1) Remove 6 mounting bolts (3) from the lower output
shaft side of transmission assembly (2).
Tool: Socket wrench
Mounting bolt (3): Width across flats 19 mm, M12
4 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 5
SEN02026-06 50 Disassembly and assembly
6 WA500-6
50 Disassembly and assembly SEN02026-06
6. No. 1 spring
Remove 10 No. 1 springs (35).
WA500-6 7
SEN02026-06 50 Disassembly and assembly
2) Remove seal rings (43) and (44) from No. 1 and No. 2
piston housing (42).
8 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 9
SEN02026-06 50 Disassembly and assembly
10 WA500-6
50 Disassembly and assembly SEN02026-06
17. Plate
Remove lower plate (76).
WA500-6 11
SEN02026-06 50 Disassembly and assembly
21. Plate
Remove upper plate (85).
24. Plate
Remove lower plate (90).
12 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 13
SEN02026-06 50 Disassembly and assembly
14 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 15
SEN02026-06 50 Disassembly and assembly
16 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 17
SEN02026-06 50 Disassembly and assembly
18 WA500-6
50 Disassembly and assembly SEN02026-06
Assembly
1. No. 6 housing assembly
1) Using push tool [1] (outer diameter: 189 mm), press fit
bearing (157) to No. 6 housing (156).
Tool: Push tool [1] (outer diameter 189 mm)
2) Using push tool [2] (outer diameter: 199 mm), press fit
bushing (158) and ball (159) to No. 6 housing (156).
Tool: Push tool [2] (outer diameter 199 mm)
2. Cage assembly
1) Install 2 seal rings (154) to cage (153).
2 Seal ring: Grease (G2-LI)
2) Using push tool [3] (inner diameter: 141 mm), press fit
No. 6 housing assembly (152) to cage assembly (153).
Tool: Push tool [3] (inner diameter 141 mm)
a Press the inner race of bearing (157).
WA500-6 19
SEN02026-06 50 Disassembly and assembly
3. Output shaft
1) Using push tool [4] (inner diameter: 71 mm), press fit
bearing (150) to output shaft (149).
Tool: Push tool [4] (inner diameter 71 mm)
2) Set No. 6 housing assembly (152) to tool [5].
Tool: Tool [5]
3) Using push tool [4] (inner diameter: 71 mm), press fit
output shaft and bearing assembly (149).
Tool: Push tool [4] (inner diameter 71 mm)
a Press bearing (150) of the output shaft.
4. Seal ring
1) Install seal ring (146) to No. 6 housing assembly (145).
2) Install seal ring (144) to No. 6 piston assembly (143).
2 Seal ring: Grease (G2-LI)
5. Guide pin
Install 5 guide pins (142).
6. No. 6 pin
Install No. 6 piston (143).
7. No. 6 hub
Install No. 6 hub (147).
20 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 21
SEN02026-06 50 Disassembly and assembly
22 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 23
SEN02026-06 50 Disassembly and assembly
23. Plate
Install lower plate (90).
26. Plate
Install upper plate (85).
24 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 25
SEN02026-06 50 Disassembly and assembly
26 WA500-6
50 Disassembly and assembly SEN02026-06
32. Plate
Install lower plate (76).
35. Plate
Install upper plate (71).
WA500-6 27
SEN02026-06 50 Disassembly and assembly
28 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 29
SEN02026-06 50 Disassembly and assembly
39. Using eyebolts [15], install No. 1 and No. 2 piston housing
assembly (42).
Tools: Sling bolt [15], 2-point chain
a While installing, support No. 2 piston (45) with the hand
to prevent it from falling.
a Drive in the dowel pin with a copper hammer.
30 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 31
SEN02026-06 50 Disassembly and assembly
32 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 33
SEN02026-06 50 Disassembly and assembly
34 WA500-6
50 Disassembly and assembly SEN02026-06
52. Sleeve
Using forcing screw [1], install 5 sleeves (1).
53. Couple the transmission assembly with the power train unit.
For details, see “Uncoupling and coupling of power train
unit”.
WA500-6 35
SEN02026-06 50 Disassembly and assembly
36 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 37
SEN02026-06 50 Disassembly and assembly
Disassembly
1. Disconnect the transfer and parking brake assembly from
the power train unit. For details, see "Disconnection and
connection of power train unit".
2. Remove strainer (1) and drain valve (2).
Tool: Socket wrench
Mounting bolt for drain valve (2): Width across flats 17 mm,
M10
4) Using push tool [2], remove outer race (7) from bearing
cage assembly (5).
Tool: Push tool [2]
38 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 39
SEN02026-06 50 Disassembly and assembly
40 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 41
SEN02026-06 50 Disassembly and assembly
15. Spring
Remove 18 outer springs (49) and 18 inner springs (50).
17. Piston
1) Using eyebolts [9], lift off piston (54).
Tools: Sling bolt [9], 2-point chain
2) Remove seal rings (55) and (56).
42 WA500-6
50 Disassembly and assembly SEN02026-06
18. Gear
Remove gear (77).
19. Plate
1) Reverse the housing.
2) Remove 4 mounting bolts (57) and plate (58).
Tool: Socket wrench
Mounting bolt (57): Width across flats 17 mm, M10
WA500-6 43
SEN02026-06 50 Disassembly and assembly
3) Remove O-ring (29), oil seal (87) and dust seal (84)
from seal cage (81).
44 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 45
SEN02026-06 50 Disassembly and assembly
Assembly
1. Outer race (Intermediate shaft side)
Using push tool [1] (outer diameter: 179 mm), press fit outer
race (22) to the case.
46 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 47
SEN02026-06 50 Disassembly and assembly
48 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 49
SEN02026-06 50 Disassembly and assembly
2) Press fit dust seal (84) to seal cage (81) by using the
push tool.
Tool: Push tool
a When installing dust seal (84), direct its lip out.
a Dimension "b" is 9.3 to 9.4 mm.
50 WA500-6
50 Disassembly and assembly SEN02026-06
3) Apply or fill grease to/into the oil seal and dust seal lip as
shown in the figure.
Portion "a":Apply grease (G2-S or G2-LI) to the lip ends
(4 places).
Portion "b":Fill grease (G2-S or G2-LI) into the spaces
"between the main lip and dust lip of oil
seal", "between the dust seal and oil seal",
and "between the double lips of dust seal"
up to 40 to 60%.
Excessively applied grease can be mistaken
for oozing oil. Take care.
Wipe off the grease forced in or out.
Portion “c”: Grease may be forced out into the space
between oil seal and dust seal.
WA500-6 51
SEN02026-06 50 Disassembly and assembly
18. Spring
1) Install 18 outer springs (49) and 18 inner springs (50).
2) Install O-ring (90).
2 O-ring: Grease (G2-LI)
19. Piston
1) Install seal rings (55) and (56) to piston (54).
a Set groove (c) of the seal ring as shown in the fig-
ure.
2 Seal ring: Grease (G2-LI)
2) Install piston (54) to cover assembly (46).
20. Plug
1) Remove 2 plugs (74).
2) Install the washers to 2 parking brake assembly mount-
ing bolts and tighten them into the plug holes.
Tool: Hexagonal wrench
Plug (74): Width across flats 8 mm
Mounting bolt: Width across flats 8 mm
a Tighten the bolts gradually and alternately.
a Pull the piston by tightening the bolts.
52 WA500-6
50 Disassembly and assembly SEN02026-06
21. Housing
1) Install housing (75) to cover (46).
22. Gear
Install gear (77).
WA500-6 53
SEN02026-06 50 Disassembly and assembly
25. Plate
1) Install plate (58) and tighten 4 mounting bolts (57).
Tool: Torque wrench (socket)
Mounting bolt (57): Width across flats 17 mm, M10
2 Mounting bolt: Adhesive (LT-2)
2) Press fit dust seal (44) to seal cage (42) by using the
push tool.
Tool: Push tool, hammer
a When installing the dust seal, direct its lip out.
a Dimension "b" is 9.3 to 9.4 mm.
54 WA500-6
50 Disassembly and assembly SEN02026-06
3) Apply or fill grease to/into the oil seal and dust seal lip
as shown in the figure.
Portion "a":Apply grease (G2-S or G2-LI) to the lip ends
(4 places).
Portion "b":Fill grease (G2-S or G2-LI) into the spaces
"between the main lip and dust lip of oil
seal", "between the dust seal and oil seal",
and "between the double lips of dust seal"
up to 40 to 60%. Excessively applied grease
can be mistaken for oozing oil. Take care.
Wipe off the grease forced in or out.
Portion “c”: Grease may be forced out into the space
between oil seal and dust seal.
WA500-6 55
SEN02026-06 50 Disassembly and assembly
28. Sleeve
1) Fit O-ring (88) to sleeve (34).
2 O-ring: Grease (G2-LI)
2) Using forcing screw [4], install sleeve (34).
Tools: Forcing screw [4]
3) Fit O-ring (87) and install parking brake emergency
release valve (33).
2 O-ring: Grease (G2-LI)
56 WA500-6
50 Disassembly and assembly SEN02026-06
WA500-6 57
SEN02026-06 50 Disassembly and assembly
58 WA500-6
50 Disassembly and assembly SEN02026-06
Removal
k Stop the machine on a level ground and lower the bucket to the ground.
WA500-6 59
SEN02026-06 50 Disassembly and assembly
60 WA500-6
50 Disassembly and assembly SEN02026-06
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for front tire (1): Width across flats 36 mm, M24
3 Front tire mounting bolt:
824 to 1,030 Nm {84.0 to 105 kgm}
[*2]
Tool: Torque wrench (socket)
Mounting bolt for drive shaft (4): Width across flats 19 mm, M12
3 Drive shaft mounting bolt: 98 to 123 Nm {10 to 12.5
kgm}
[*3]
Tool: Torque wrench (socket)
Mounting bolt (6): Width across flats 55 mm, M36
3 Front axle mounting bolt:
2,450 to 3,038 Nm {250 to 310 kgm}
q Bleeding air
Bleed air from the brake circuit. For details, see Testing and
adjusting, "Bleeding air from brake circuit".
WA500-6 61
SEN02026-06 50 Disassembly and assembly
62 WA500-6
50 Disassembly and assembly SEN02026-06
Removal
k Stop the machine on a level ground and lower the bucket to the ground.
WA500-6 63
SEN02026-06 50 Disassembly and assembly
10. Sling rear axle assembly (8) and support rear support (9)
with jack [3].
Tools: 2-point chain, Jack [3]
11. Remove support mounting bolts (10), disconnect the sup-
port and rear axle assembly from the machine, and lower
the jack and crane slowly to remove the assembly.[*3]
Tool: Socket wrench
Mounting nut (10) for support: Width across flats 46 mm,
M30
12. Sling the left (right) side of the axle housing, support the
other side with a jack or a forklift, and pull out the rear axle
and support assembly to the side of the machine.
Tool: 2-point chain
4 Rear axle and support assembly: 2,400 kg
64 WA500-6
50 Disassembly and assembly SEN02026-06
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for rear tire: Width across flats 36 mm, M24
3 Rear tire mounting bolt: 824 to 1,030 Nm {84.0 to 105
kgm}
[*2]
Mounting bolt for drive shaft: Width across flats 19 mm, M12
3 Drive shaft mounting bolt: 98 to 123 Nm {10 to 12.5
kgm}
[*3]
Mounting nut for axle (Support): Width across flats 46 mm, M30
3 Axle (Support) mounting bolt:
1,519 to 1,911 Nm {155 to 195 kgm}
q Bleeding air
Bleed air from the brake circuit. For details, see Testing and
adjusting, "Bleeding air from brake circuit".
WA500-6 65
SEN02026-06
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
66
SEN02027-06
WA500-6
WA500-6 1
SEN02027-06 50 Disassembly and assembly
a This section describes the removal and installation procedures for the front differential assembly.
Remove and install the rear differential assembly similarly.
2 WA500-6
50 Disassembly and assembly SEN02027-06
Removal
k Stop the machine on a level ground, set the lock bar to the frame, and lock the tires with chocks.
WA500-6 3
SEN02027-06 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Drain plug (1): Width across flats 36 mm
3 Plug (1): 58.8 to 78.4 Nm {6 to 8 kgm}
[*2]
Tool: Torque wrench (socket)
Mounting bolt (2): Width across flats 19 mm, M12
Mounting bolt (2): 98 to 123 Nm {10 to 12.5 kgm}
[*3]
Tool: Torque wrench (socket)
Mounting bolt (5): Width across flats 30 mm, M20
Mounting bolt (5): 490 to 608 Nm {50 to 62 kgm}
[*4]
Adjusting clearance adjustment bolt
1) Tighten clearance adjustment bolt (7) to cap (9) and
then return it by 20 – 30° to make clearance (a).
Clearance (a): 0.08 – 0.13 mm
2) Tighten nut (8).
Tool: Torque wrench (open-end)
Lock nut (8): Width across flats 46 mm, M30
3 Nut (8): 343 to 441 Nm {35 to 45 kgm}
4 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 5
SEN02027-06 50 Disassembly and assembly
6 WA500-6
50 Disassembly and assembly SEN02027-06
Disassembly
1. Set differential assembly (1) to tool H1.
Tools: Belt sling, special tool H1
4 Differential assembly: 430 kg
2) Loosen nut (4) with a bar until you can rotate it with
your fingers.
Tool: Bar
3) Sling the differential gear and case assembly.
Tool: Belt sling
4) Remove mounting bolts (5) and cap (6).
Tool: Socket wrench
Mounting bolt (5): Width across flats 46 mm, M30
a Make marks on the right and left caps.
5) Remove nut (4).
WA500-6 7
SEN02027-06 50 Disassembly and assembly
4) Remove thrust plate (12) and dowel pin (13) from gear
case cover A (10).
5. Pressure ring A
Remove pressure ring A (16).
6. Side gear A
Remove side gear A (17).
8 WA500-6
50 Disassembly and assembly SEN02027-06
8. Side gear B
Remove side gear B (20).
9. Pressure ring B
Remove pressure ring B (21).
WA500-6 9
SEN02027-06 50 Disassembly and assembly
12. Coupling
1) Remove mounting bolt (31) and holder (32).
Tool: Socket wrench
Mounting bolt (31): Width across flats 36 mm, M24
2) Remove shim (33), O-ring (34) and coupling (35).
10 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 11
SEN02027-06 50 Disassembly and assembly
Assembly
1. Bevel gear assembly
1) Using push tool [10] (inner diameter: 131 mm), press fit
bearing (27) to gear case cover B (29).
Tool: Push tool [10] (inner diameter 131 mm)
a Press fit the inner race of the bearing.
4. Pressure ring B
Install pressure ring B (21).
12 WA500-6
50 Disassembly and assembly SEN02027-06
5. Side gear B
Install side gear B (20).
a When installing, mesh the internal teeth of the disc with
the gear spaces.
7. Side gear A
Install side gear A (17).
8. Pressure ring A
Install pressure ring A (16).
WA500-6 13
SEN02027-06 50 Disassembly and assembly
14 WA500-6
50 Disassembly and assembly SEN02027-06
2) Install dowel pin (13) and thrust plate (12) to gear case
cover A (10).
Tool: Hammer
a When installing, apply grease (G2-LI) thinly to the
thrust plate to prevent it from falling.
WA500-6 15
SEN02027-06 50 Disassembly and assembly
16 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 17
SEN02027-06 50 Disassembly and assembly
2) Coupling
1] Install coupling (35).
2] Install O-ring (34) and shim (33) removed for dis-
assembly.
3] Install holder (32) and tighten mounting bolts (31).
a While rotating the pinion shaft 20 – 30 turns,
tighten mounting bolts (31) gradually.
2 O-ring: Grease (G2-LI)
2 Mounting bolt: Adhesive (LT-2)
Tool: Torque wrench (socket)
Mounting bolt (31): Width across flats 36 mm, M24
18 WA500-6
50 Disassembly and assembly SEN02027-06
3 Mounting bolt:
824 to 1,030 Nm {84.0 to 105 kgm}
WA500-6 19
SEN02027-06 50 Disassembly and assembly
20 WA500-6
50 Disassembly and assembly SEN02027-06
14. Lock
After finishing all adjustments, install lock (3) and tighten
mounting bolts (2).
Tool: Torque wrench (socket)
Mounting bolt (2): Width across flats 13 mm, M8
3 Mounting bolt: 27 to 34 Nm {2.8 – 3.5 kgm}
WA500-6 21
SEN02027-06 50 Disassembly and assembly
22 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 23
SEN02027-06 50 Disassembly and assembly
Disassembly
1. Set differential assembly (1) to tool H1.
Tools: Belt sling, special tool H1
4 Differential assembly: 390 kg
2) Loosen nut (4) with a bar until you can rotate it with
your fingers.
Tool: Bar
3) Sling the differential gear and case assembly.
Tool: Belt sling
4) Remove mounting bolts (5) and cap (6).
Tool: Socket wrench
Mounting bolt (5): Width across flats 46 mm, M30
a Make distinction marks on the right and left caps.
5) Remove nut (4).
24 WA500-6
50 Disassembly and assembly SEN02027-06
4. Side gear A
Remove side gear A (14).
6. Side gear B
Remove side gear B (18).
WA500-6 25
SEN02027-06 50 Disassembly and assembly
8. Coupling
1) Remove mounting bolt (31) and holder (32).
Mounting bolt (31): Width across flats 36 mm, M24
2) Remove shim (33), O-ring (34) and coupling (35).
9. Pinion assembly
1) Remove 18 mounting bolts (36).
Mounting bolt (36): Width across flats 24 mm, M16
2) Using forcing screws [2], disconnect pinion assembly
(37).
Tools: Forcing screw [2]
26 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 27
SEN02027-06 50 Disassembly and assembly
Assembly
1. Bevel gear assembly
1) Using push tool [10] (inner diameter: 131 mm), press fit
bearing (22) to gear case cover B (24).
Tool: Push tool [10] (inner diameter 131 mm)
a Press fit the inner race of the bearing.
3. Side gear B
Install side gear B (18).
28 WA500-6
50 Disassembly and assembly SEN02027-06
5. Side gear A
Install side gear A (14).
2) Install dowel pin (13) and thrust plate (12) to gear case
cover A (10).
Tool: Hammer
a When installing, apply grease (G2-LI) thinly to the
thrust plate to prevent it from falling.
WA500-6 29
SEN02027-06 50 Disassembly and assembly
30 WA500-6
50 Disassembly and assembly SEN02027-06
8. Pinion assembly
1) Assemble the pinion assembly according to the follow-
ing procedure.
1] Using push tool [6] (inner diameter: 101 mm),
press fit bearing (41) to pinion shaft (40).
Tool: Push tool [6] (inner diameter 101 mm)
WA500-6 31
SEN02027-06 50 Disassembly and assembly
2) Coupling
1] Install coupling (35).
2] Install O-ring (34) and shim (33) removed for dis-
assembly.
3] Install holder (32) and tighten mounting bolts (31).
a While rotating the pinion shaft 20 – 30 turns,
tighten mounting bolts (31) gradually.
2 O-ring: Grease (G2-LI)
2 Mounting bolt: Adhesive (LT-2)
Tool: Torque wrench (socket)
Mounting bolt (31): Width across flats 36 mm, M24
3 Mounting bolt:
824 to 1,030 Nm {84.0 to 105 kgm}
32 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 33
SEN02027-06 50 Disassembly and assembly
34 WA500-6
50 Disassembly and assembly SEN02027-06
10. Lock
After finishing all adjustments, install lock (3) and tighten
mounting bolts (2).
Tool: Torque wrench (socket)
Mounting bolt (2): Width across flats 13 mm, M8
3 Mounting bolt: 27 to 34 Nm {2.8 to 3.5 kgm}
WA500-6 35
SEN02027-06 50 Disassembly and assembly
36 WA500-6
50 Disassembly and assembly SEN02027-06
Disassembly
k Stop the machine on a level ground, set the lock bar to the frame, and lock the tires with chocks.
2. Draining oil
Remove drain plug (2) and drain the oil.
Tool: Socket wrench
Drain plug (2): Width across flats 36 mm
a Set the drain plug at the bottom.
6 Axle oil
Front: 98 l
Rear: 85 l
3. Cover
Remove 7 bolts (3) and cover (4).
Tool: Socket wrench
Bolt (3): Width across flats 19 mm, M12
4. Drive shaft
1) Using forcing screw [2], pull out drive shaft (5).
Tools: Forcing screw [2]
2) Using sling [3], remove drive shaft (5).
Tool: Lifting tool [3]
3) Remove spacer (6), sun gear (7) and snap ring (8) from
drive shaft (5).
Tool: Snap ring pliers
WA500-6 37
SEN02027-06 50 Disassembly and assembly
6. Ring gear
1) Using tools H3, fix wheel hub (15) and brake housing
(16).
Tool: Special tool H3
a Install tools H3 to 3 places at regular intervals.
a Keep tools H3 unistalled until steps 1 to 2 "Wheel
Bearing Adjustment Procedure" are finished.
38 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 39
SEN02027-06 50 Disassembly and assembly
Assembly
1. Ring gear
1) Assemble the ring gear assembly according to the fol-
lowing procedure.
1] Using push tool [7] (inner diameter: 221 mm),
press fit bearing (24) to ring gear hub (23).
Tool: Push tool [7]
a After press fitting the bearing, check that there
is no clearance between it and hub.
40 WA500-6
50 Disassembly and assembly SEN02027-06
WA500-6 41
SEN02027-06 50 Disassembly and assembly
2. Planetary carrier
1) Assemble the planetary carrier assembly according to
the following procedure.
1] Set planetary gear (12) and bearing (14) to the car-
rier case.
2] Fit ball (13) to shaft (11) and press fit them to the
carrier case.
Use lifting tool [3] to mount drive shaft (5).
a Press fit shaft (11) with the ball hole out. Stop
before the hole and adjust the hole.
a After press fitting the shaft, check that the plane-
tary gear rotates lightly.
42 WA500-6
50 Disassembly and assembly SEN02027-06
3. Drive shaft
1) Install snap ring (8), sun gear (7) and spacer (6) to
drive shaft (5).
2) Using sling [3], install drive shaft (5).
Tool: Lifting tool [3]
3) Using guide bolt [2], set the spline at the end of drive
shaft (5) and push it in.
Tool: Guide bolt [2]
a If the sun gear does not mesh with the planetary
gear, rotate the wheel hub with the hand to mesh
those gears.
4. Cover
1) Fit the O-ring, install cover (4), and tighten 7 bolts (3).
Tool: Torque wrench (socket)
Bolt (3): Width across flats 19 mm, M12
2 O-ring: Grease (G2-LI)
3 Mounting bolt: 98 to 123 Nm {10 to 12.5 kgm}
2) Install drain plug (2).
Tool: Torque wrench (socket)
Drain plug (2): Width across flats 36 mm
a Set the drain plug at the bottom.
3 Drain plug (2): 58.8 to 78.4 Nm {6 to 8 kgm}
WA500-6 43
SEN02027-06
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 10-20 (01)
44
SEN02028-02
WA500-6
Brake system
Removal and installation of brake assembly (front and rear).......................................................................... 2
Disassembly and assembly of brake assembly (front and rear) ..................................................................... 9
Disassembly and assembly of slack adjuster assembly ............................................................................... 18
Disassembly and assembly of brake accumulator charge valve assembly .................................................. 19
WA500-6 1
SEN02028-02 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02028-02
WA500-6 3
SEN02028-02 50 Disassembly and assembly
Removal
k Stop the machine on a level ground, set the lock bar to the frame, and lock the tires with chocks.
4 WA500-6
50 Disassembly and assembly SEN02028-02
9. Remove bearing (9) and retainer (10) from axle (8). [*4]
WA500-6 5
SEN02028-02 50 Disassembly and assembly
Installation
1. Install retainer (10) and bearing (9) to axle (8).
a Drip 6 cc of axle oil (AXO80) on the bearing, and turn
the bearing approximately 10 turns.
3. Set brake and wheel hub assembly (7) by using sling H16.
4 Brake and wheel hub assembly (7): 350 kg
4. Install with bolts (6) (15 pieces).
Tool: Socket wrench
Bolt (6): Width across flats 30 mm, M20
3 Bolt (6): 490 to 608 Nm {50 to 62 kgm}
6 WA500-6
50 Disassembly and assembly SEN02028-02
8. Install O-ring H11, adapter H10, nipple H12, and hose H13.
11. Adjust the brake disc wear indicator according to the follow-
ing procedure.
1) Operate pump H9, and apply oil pressure of 5.39 to
5.88 MPa {55 to 60 kg/cm2} to brake oil port (d).
2) Remove cap (11), and loosen nut (13).
Tool: Torque wrench (open-end)
3) With shaft (12) fully pushed in, turn guide (14) and flush
guide end face (a) with shaft groove end (b) at (c).
4) Tighten nut (13).
Tool: Torque wrench (open-end)
3 Nut (13): 58.8 to 78.4 Nm {6.0 to 8.0 kgm}
5) Install the cap (11).
3 Cap (11): 29.4 to 39.2 Nm {3.0 to 4.0 kgm}
WA500-6 7
SEN02028-02 50 Disassembly and assembly
8 WA500-6
50 Disassembly and assembly SEN02028-02
WA500-6 9
SEN02028-02 50 Disassembly and assembly
10 WA500-6
50 Disassembly and assembly SEN02028-02
Disassembly
1. Remove the brake assembly. For details, see "Removal and
installation of brake assembly (Front and rear)".
2. Remove tool H3 (used to fix the wheel hub and brake hous-
ing) installed for the above work.
3. Cylinder assembly
1) Remove 24 mounting bolts (1).
Tool: Socket wrench
Mounting bolt (1): Width across flats 22 mm, M14
2) Using forcing screws [1], disconnect cylinder assembly
(2).
Tools: Forcing screw [1]
3) Using eyebolts [2], remove cylinder assembly (2).
Tools: Sling bolt [2], 2-point chain
WA500-6 11
SEN02028-02 50 Disassembly and assembly
5. Outer gear
1) Using sling [5], remove outer gear (16).
Tool: Lifting tool [5]
2) Remove oil seal (17) and floating seal (18) from outer
gear (16).
6. Wheel hub
1) Remove bearing outer races (19) and (20).
12 WA500-6
50 Disassembly and assembly SEN02028-02
WA500-6 13
SEN02028-02 50 Disassembly and assembly
Assembly
1. Wheel hub
1) Using push tool [6] (outer diameter: 313 mm), press fit
outer race (20) to wheel hub (21).
Tool: Push tool [6] (outer diameter 313 mm)
2) Using push tool [7] (outer diameter: 189 mm), press fit
outer race (19) to wheel hub (21).
Tool: Push tool [7] (outer diameter 189 mm)
3) Install O-ring (25) and seal cage (23) to wheel hub (21).
2 O-ring: Grease (G2-LI)
4) Tighten 6 mounting bolts (22).
Tool: Torque wrench (socket)
Mounting bolt (22): Width across flats 17 mm, M10
3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}
2. Outer gear
1) Using tool H2, install oil seal (17) to outer gear (16).
Tool: Special tool H2
2 Seal lip surface: Grease (G2-LI)
14 WA500-6
50 Disassembly and assembly SEN02028-02
4. Cylinder assembly
1) Assemble the cylinder assembly according to the fol-
lowing procedure.
1] Install seal rings (10) and (11) to inner cylinder (8).
2 Seal ring: Grease (G2-LI)
2] Install seal ring (9) to piston (6).
2 Seal ring: Grease (G2-LI)
WA500-6 15
SEN02028-02 50 Disassembly and assembly
16 WA500-6
50 Disassembly and assembly SEN02028-02
5. Install tool H3 (to fix the wheel hub and brake housing).
Tool: Special tool H3
WA500-6 17
SEN02028-02 50 Disassembly and assembly
a Only the precautions for assembling the slack adjuster assembly are described in this section.
18 WA500-6
50 Disassembly and assembly SEN02028-02
a Only the precautions for assembling the brake accumulator charge valve assembly are described in this
section.
WA500-6 19
SEN02028-02 50 Disassembly and assembly
20 WA500-6
50 Disassembly and assembly SEN02028-02
WA500-6 21
SEN02028-02
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
22
SEN02029-05
WA500-6
WA500-6 1
SEN02029-05 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02029-05
WA500-6 3
SEN02029-05 50 Disassembly and assembly
Removal
k Stop the machine on a level ground and lower the bucket.
k Disconnect the cable from the negative (–) terminal of the battery.
4 WA500-6
50 Disassembly and assembly SEN02029-05
14. Remove bolts (21) and (22) and retainer (22) and pull out
lower hinge pin. [*3]
Tool: Socket wrench
Bolts (21), (22): Width across flats 24 mm, M16
a After removing the bolts, pull out the pin while adjusting
the height of the front frame and rear frame with the
jacks.
WA500-6 5
SEN02029-05 50 Disassembly and assembly
18. Pull out front frame (30) forward slowly to disconnect it from
rear frame (31).
a When disconnecting the front frame, balance it care-
fully.
a Check that all the pipings and wiring harnesses are dis-
connected.
a Move the front frame about 100 mm each time.
19. Remove bushing (32) and collar from the rear frame.
6 WA500-6
50 Disassembly and assembly SEN02029-05
20. Remove bolts (33) and remove retainer (34) from the front
frame. [*6]
Tool: Socket wrench
Bolt (33): Width across flats 24 mm, M16
a Check the quantity and thickness of the shims between
the retainer and frame.
21. Remove dust seal (35) from the retainer. [*7]
22. Remove dust seal (36) from the frame. [*8]
23. Remove bearing (37) from the frame. [*9]
24. Remove bolts (38) and remove retainer (39) from the front
frame. [*10]
Tool: Socket wrench
Bolt (38): Width across flats 22 mm, M14
a Check the quantity and thickness of the shims between
the retainer and frame.
25. Remove dust seal (40) from the retainer. [*11]
26. Remove bushing (41) and dust seal (42) from the front
frame. [*12]
27. Remove bearing (43) from the frame. [*13]
WA500-6 7
SEN02029-05 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tools: Torque wrench (socket)
Mounting bolt for drive shaft: Width across flats 19 mm, M12
3 Drive shaft mounting bolt: 98 to 123 Nm {10 to 12.5
kgm}
a Tighten the drive shaft according to the following procedure.
1) Check that the seats of the mating yoke and drive shaft
spider are free from rust, foreign matter (masking mate-
rial), bruise, etc.
2) Set the key way of the yoke vertically, place the drive
shaft on the bottom of the yoke socket, and fit the key
in the key way.
3) Insert the 4 upper and lower bolts and finger tighten
them until the seats of the spider and yoke are fitted.
a At this time, if the key way and socket of the yoke are
tight and the spider is not fitted easily, drive in the spi-
der with a plastic hammer (or a copper hammer). (Do
not use a steel hammer which can damage the cross
bearing.)
a If the spider is not fitted perfectly at this time, it will float
and its seat will be parted from the yoke when the other
parts are tightened. Accordingly, tighten the spider
securely.
4) Basically, tighten the bolts in the diagonal order.
[*2]
a Adjust the shim so that clearances (a) and (b) between the
cylinder and mounting face of the frame will be 0.5 mm or
less respectively.
[*3]
Tools: Torque wrench (socket)
Mounting bolt for retainer: Width across flats 24 mm, M16
Tools: Torque wrench (socket)
Mounting bolt for pin: Width across flats 27 mm, M18
q Install the lower hinge pin according to the following proce-
dure.
1) Install bushing (32) and collar (44) to the frame.
2) Align the front frame and rear frame.
k When aligning the pin holes, use a bar. Never
insert your fingers in the pin holes.
3) Fit retainer (23) to hinge pin (45), insert them in the pin
hole, and tighten bolts (22).
2 Periphery of hinge pin: Grease (G2-LI)
2 Threaded part of retainer mounting bolt:
Adhesive (LOCTITE 262)
3 Retainer mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
8 WA500-6
50 Disassembly and assembly SEN02029-05
[*4], [*5]
q Install the upper hinge pin according to the following proce-
dure.
1) Measure the thickness of retainer (28) in advance at 3
places of Ø6.5 hole of the retainer.
2) Install bushing (29) to the upper hinge.
3) Temporarily install retainer (28) to hinge pin (46) with
bolts (27) and insert hinge pin (46) in the pin hole.
2 Periphery of hinge pin: Grease (G2-LI)
4) Tighten bolts (27) to the specified torque.
a While tightening the bolts, check the behavior of
each of them.
5) After tightening the bolts to the specified torque, mea-
sure the clearance between the retainer and rear frame
at 3 places of Ø6.5 hole.
6) Select shims so that their total thickness will be 0.08 –
0.18 mm less than the measured clearance.
7) Remove the retainer, install shim (47), and tighten the
retainer mounting bolts to the specified torque.
2 Threaded part of retainer (26) mounting bolt:
Adhesive (LOCTITE 262)
Tools: Torque wrench (socket)
Bolt (26): Width across flats 24 mm, M16
3 Retainer (26) mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
2 Threaded part of pin mounting bolt (27):
Adhesive (LOCTITE 262)
Tools: Torque wrench (socket)
Bolt (27): Width across flats 27 mm, M18
3 Pin mounting bolt (27):
343 to 426 Nm {35 to 43.5 kgm}
2 Threaded part of pin mounting bolt (24):
Adhesive (LOCTITE 262)
Tools: Torque wrench (socket)
Bolt (24): Width across flats 27 mm, M18
3 Pin mounting bolt (24):
343 to 426 Nm {35 to 43.5 kgm}
WA500-6 9
SEN02029-05 50 Disassembly and assembly
10 WA500-6
50 Disassembly and assembly SEN02029-05
q Bleeding air
Bleed air from the brake circuit. For details, see Testing and
adjusting, "Bleeding air from each part".
WA500-6 11
SEN02029-05
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
12
SEN02030-05
WA500-6
Hydraulic system
Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of hydraulic cooling pump assembly ....................................................................... 8
Removal and installation of cooling fan pump assembly ...............................................................................11
Removal and installation of work equipment pump assembly ...................................................................... 14
Removal and installation of steering, torque converter charge and EPC pump assembly ........................... 18
Removal and installation of work equipment valve assembly ....................................................................... 22
Disassembly and assembly of work equipment control valve assembly....................................................... 27
Disassembly and assembly of steering cylinder assembly ........................................................................... 31
Disassembly and assembly of lift arm and bucket cylinder assembly .......................................................... 36
Removal and installation of steering control valve assembly........................................................................ 45
WA500-6 1
SEN02030-05 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02030-05
WA500-6 3
SEN02030-05 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
4 WA500-6
50 Disassembly and assembly SEN02030-05
10. Disconnect hose clamps (10) and (11) fixed together with
the hydraulic tank.
Tool: Socket wrench
Hose clamp (10), (11): Width across flats 17 mm, M10
12. Disconnect hoses (13), (14), (15), (16), (17) and (18) and all
of the hose clamps fixed together with the hydraulic tank.
Tools: Open-end wrench, special tool AA, AB, AD, AE
Hose (13): Width across flats 22 mm, nominal 03
Hose (14): Width across flats 32 mm, nominal 05
Hose (15): Width across flats 19 mm, nominal 02
Hose (16): Width across flats 22 mm, nominal 03
Hose (17): Width across flats 36 mm, nominal 06
Hose (18): Width across flats 22 mm, nominal 03
WA500-6 5
SEN02030-05 50 Disassembly and assembly
6 WA500-6
50 Disassembly and assembly SEN02030-05
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Hose clamp: Width across flats 8 mm
3 Hose clamp: 10.5 Nm {1.07 kgm}
[*2]
2 Hose clamp mounting bolt thread: Adhesive agent (LT-2)
Tool: Torque wrench (socket)
Hose clamp: Width across flats 17 mm, M10
3 Hose clamp: 101 Nm {10.3 kgm}
3 Hose clamp mounting bolt: 101 Nm {10.3 kgm}
[*3]
a Adjust the clearance between the hydraulic tank and rear
frame to 0.5 mm or less with the shim.
q Bleeding air
Bleed air from the brake circuit. For details, see Testing and
adjusting, "Bleeding air from work equipment circuit".
WA500-6 7
SEN02030-05 50 Disassembly and assembly
8 WA500-6
50 Disassembly and assembly SEN02030-05
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
WA500-6 9
SEN02030-05 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for pump: Width across flats 19 mm, M12
3 Pump mounting bolt: 235 to 285 Nm {23.5 to 29.5 kgm}
q Bleeding air
Bleed air from the related circuit. For details, see Testing
and adjusting, "Bleeding air from work equipment circuit".
10 WA500-6
50 Disassembly and assembly SEN02030-05
WA500-6 11
SEN02030-05 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
12 WA500-6
50 Disassembly and assembly SEN02030-05
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for fan pump: Width across flats 19 mm, M12
3 Pump mounting bolt: 98 to 123 Nm {10 to 12.5 kgm}
q Bleeding air
Bleed air from the related circuit. For details, see Testing
and adjusting, "Bleeding air from hydraulic drive fan circuit".
WA500-6 13
SEN02030-05 50 Disassembly and assembly
14 WA500-6
50 Disassembly and assembly SEN02030-05
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
WA500-6 15
SEN02030-05 50 Disassembly and assembly
10. Remove the 2 pump mounting bolts and lift off work equip-
ment pump assembly (8). [*1]
Tool: Socket wrench, wire
Mounting bolt for pump assembly (8): Width across flats 30
mm, M20
4 Work equipment pump assembly: 110 kg
16 WA500-6
50 Disassembly and assembly SEN02030-05
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for work equipment pump: Width across flats 30
mm, M20
3 Pump mounting bolt: 455 to 565 Nm {46.5 to 58 kgm}
q Bleeding air
Bleed air from the related circuit. For details, see Testing
and adjusting, "Bleeding air from work equipment circuit".
WA500-6 17
SEN02030-05 50 Disassembly and assembly
18 WA500-6
50 Disassembly and assembly SEN02030-05
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
WA500-6 19
SEN02030-05 50 Disassembly and assembly
20 WA500-6
50 Disassembly and assembly SEN02030-05
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for pump assembly (11): Width across flats 30
mm, M20
3 Pump mounting bolt: 235 to 285 Nm {23.5 to 29.5 kgm}
q Bleeding air
Bleed air from the related circuit. For details, see Testing
and adjusting, "Bleeding air from steering cylinder circuit".
WA500-6 21
SEN02030-05 50 Disassembly and assembly
22 WA500-6
50 Disassembly and assembly SEN02030-05
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
k See "Releasing residual pressure in work equipment circuit" in "Testing and adjusting", and
release residual pressure from work equipment circuit and ECSS (travel damper) circuit.
WA500-6 23
SEN02030-05 50 Disassembly and assembly
14. Remove hoses (21) and (22) and brackets (23) and (24).
Tool: Socket wrench
Flange bolt for hose (21): Width across flats 19 mm, M12
Flange bolt for hose (22): Width across flats 17 mm, M12
Brackets (23), (24): Width across flats 19 mm, M12
a Cover hose separable part with a plastic bag to prevent
oil from leaking.
24 WA500-6
50 Disassembly and assembly SEN02030-05
19. Set a wooden block and steel plate [1] to the frame. Sling
work equipment valve assembly (35) and pull it out to this
side to remove.
Tool: Steel plate [1]
4 Work equipment valve assembly: 160 kg
WA500-6 25
SEN02030-05 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level. Run the
engine to circulate the oil through the system. Then, check
the oil level again.
q Air bleeding
q Bleed the air from the circuit between the valve and the
hydraulic cylinder. For details, see Testing and adjust-
ing, "Bleeding air from work equipment circuit".
26 WA500-6
50 Disassembly and assembly SEN02030-05
a Only the precautions for assembling the work equipment control valve assembly are described in this
section.
WA500-6 27
SEN02030-05 50 Disassembly and assembly
28 WA500-6
50 Disassembly and assembly SEN02030-05
q Plugs
a Thoroughly degrease and dry the plugs and threaded parts
of the valve mounting holes with denatured alcohol etc.
a Do not apply oil pressure for 2 hours after installing the
plugs.
2 Lift arm spool plug (3): LOCTITE No. 638
2 Bucket spool plug (4): LOCTITE No. 638
qECSS valve
Loosen locknut (6) and tighten plug (5) to the specified
torque. Then, tighten locknut (6) to the specified torque. At
this time, check that no clearance is made at parts (c) on
the seat surface (to prevent oil from flowing in through the
seat of plug (5)).
3 Plug (5): 19.6 to 27.5 Nm {2.0 to 2.8 kgm}
3 Locknut (6): 19.6 to 27.5 Nm {2.0 to 2.8 kgm}
WA500-6 29
SEN02030-05 50 Disassembly and assembly
30 WA500-6
50 Disassembly and assembly SEN02030-05
U 5 • Bolt 01010-50816 1
1 Push tool kit 790-201-1702 1 t
2 • Push tool 790-201-1781 1 t
5
4 • Gripz 790-101-5021 1
5 • Bolt 01010-50816 1
1 Expander 790-720-1000 1 t
6 2 Ring 796-720-1660 1 t
3 Clamp 07281-01159 1 t
7 Wrench assembly 790-330-1100 1 t
WA500-6 31
SEN02030-05 50 Disassembly and assembly
Disassembly
1. Set cylinder assembly (1) to tool U1.
Tools: Special tool U1, belt sling
2. Using tool U7, remove cylinder head (2) from the cylinder.
Tool: Special tool U7
3. Pull cylinder head and piston rod assembly (3) out of cylin-
der (4) and lift it off.
Tool: Belt sling
a Since oil flows out when the piston rod assembly is
pulled out of the cylinder, prepare an oil receiver.
4. Remove cylinder (4) from tool U1.
Tool: Belt sling
6. Remove nut (5) and then remove piston assembly (6) and
cylinder head assembly (7) from rod (8).
32 WA500-6
50 Disassembly and assembly SEN02030-05
WA500-6 33
SEN02030-05 50 Disassembly and assembly
Assembly
a When assembling, coat the sliding surfaces of each part with engine oil and take care not to damage the
rod packings, dust seals, and O-rings.
3) Install tool U6-2 to the piston ring and shrink the piston
ring with clamp U6-3.
Tools: Torque wrench (socket), special tool U3, belt
sling
4) Install wear ring (9).
34 WA500-6
50 Disassembly and assembly SEN02030-05
5. Using torque multiplier [1] and socket U3, tighten nut (5).
Tools: Special tool U1, torque multiplier [1], special tool U3
3 Piston nut:
6. Remove piston rod and head assembly (3) from tool U1.
Tool: Belt sling
7. Set cylinder (4) to tool U1.
Tools: Special tool U1, belt sling
8. Sling piston rod and head assembly (3) and install it to cylin-
der (4).
Tool: Belt sling
WA500-6 35
SEN02030-05 50 Disassembly and assembly
36 WA500-6
50 Disassembly and assembly SEN02030-05
Disassembly
1. Set cylinder assembly (1) to tool U1.
Tools: Special tool U1, belt sling
2. Remove mounting bolt (2) of the cylinder head.
Tool: Socket wrench
Mounting bolt (2) for lift cylinder: Width across flats 30 mm,
M20
Mounting bolt (2) for bucket cylinder: Width across flats 36
mm, M24
3. Set the cylinder to tool U1 and pull cylinder head and piston
rod assembly (3) out of cylinder (4) and lift it off.
Tool: Belt sling
a Since oil flows out when the piston rod assembly is
pulled out of the cylinder, prepare an oil receiver.
WA500-6 37
SEN02030-05 50 Disassembly and assembly
38 WA500-6
50 Disassembly and assembly SEN02030-05
WA500-6 39
SEN02030-05 50 Disassembly and assembly
Assembly
a When assembling, coat the sliding surfaces of each part with engine oil and take care not to damage the
U-packings, dust seals, and O-rings.
40 WA500-6
50 Disassembly and assembly SEN02030-05
5) Using push tool U5, install dust seal (17) to the cylinder
head and fix it with snap ring (22).
Tools: Special tool U5, snap ring pliers
WA500-6 41
SEN02030-05 50 Disassembly and assembly
42 WA500-6
50 Disassembly and assembly SEN02030-05
4] After making the hole, remove the all chips and dirt
and clean thoroughly.
5. Set cylinder (4) to tool U1 and sling cylinder head and pis-
ton rod assembly (3) and install it to the cylinder.
Tool: Belt sling
WA500-6 43
SEN02030-05 50 Disassembly and assembly
44 WA500-6
50 Disassembly and assembly SEN02030-05
WA500-6 45
SEN02030-05 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
6. Disconnect hoses (7), (8), (9), (10), (11), (12) and (13).
Tool: Socket wrench
Flange bolt for hose (7): Width across flats 14 mm, M10
a Cover hose separable part with a plastic bag to prevent
oil from leaking.
Tools: Open-end wrench, special tools AB, AD, AE
Hoses (8), (12), (13): Width across flats 22 mm, nominal 03
Hoses (9), (10): Width across flats 36 mm, nominal 06
Hose (11): Width across flats 32 mm, nominal 05
7. Disconnect tube (14).
Tool: Socket wrench
Flange bolt for tube (14): Width across flats 17 mm, M10
a Cover tube separable part with a plastic bag to prevent
oil from leaking.
46 WA500-6
50 Disassembly and assembly SEN02030-05
Installation
q Carry out installation in the reverse order to removal.
q Bleeding air
Bleed air from the related circuit. For details, see Testing
and adjusting, "Bleeding air from steering cylinder circuit".
WA500-6 47
SEN02030-05
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
48
SEN02031-02
WA500-6
Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
Removal and installation of large counterweight assembly ............................................................................ 7
Removal and installation of small counterweight assembly .......................................................................... 10
WA500-6 1
SEN02031-02 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02031-02
Removal
k Stop the machine on a level ground and lower the bucket to the ground.
k Set the lock bar to the frame, apply the parking brake, and lock the tires with chocks.
5. Sling bucket cylinder (5), pull out pin (6), and disconnect the
bucket cylinder from the bell crank.
Tools: Belt sling, socket wrench
Mounting bolt for pin (6): Width across flats 24 mm, M16
a After disconnecting the bucket cylinder, start the engine
and retract the piston rod.
6. Fix bucket cylinder (5) to the frame with a nylon sling etc.
Tool: Belt sling
WA500-6 3
SEN02031-02 50 Disassembly and assembly
7. Set support stand [1] under the lift arm end and release the
residual pressure in the hydraulic piping.
Tool: Support stand [1]
13. Sling lift arm, bell crank and bucket link assembly (14), pull
out right and left pins (15), and lift off the assembly. [*4]
Tools: Chain, block [2], socket wrench
Mounting bolt for pin (15): Width across flats 24 mm, M16
a When slinging above assembly, insert block [2] in the
bell crank.
a If any shim is inserted, check its quantity and thickness.
4 Lift arm, bell crank and bucket link assembly:
3,250 kg
4 WA500-6
50 Disassembly and assembly SEN02031-02
14. Sling bucket link assembly (16), pull out pin (17), and
remove the assembly from the bell crank.
Tools: Chain, socket wrench
Mounting bolt for pin (17): Width across flats 24 mm, M16
4 Bucket link: 160 kg
15. Sling bell crank (18), pull out pin (19), and remove the bell
crank from the lift arm.
Tools: Chain, socket wrench
Mounting bolt for pin (19): Width across flats 30 mm, M20
4 Bell crank: 800 kg
16. Remove dust seal (21) and bushing (22) from lift arm (20).
[*5]
17. Remove dust seal (23) and bushing (24) from bell crank
(18).
18. Remove dust seal (25) and bushing (26) from bucket link
(16).
WA500-6 5
SEN02031-02 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
k When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.
k When starting the engine, check that the directional lever is in neutral and the parking brake is
applied.
[*1]
Sling bucket link (16) and install cord rings (27) while aligning
the holes for pin (1). Insert a shim so that clearances (a) on the
right and left sides will be the same, and then install pin (1) and
lock it with the bolt.
a Take care that the cord ring will not be caught.
a Clearance (a): Max. 1.5 mm
[*2]
Operate the control lever to align the holes for bucket mounting
pin (2) and install cord rings (28). Insert a shim so that clear-
ances (b) on the right and left sides will be the same, and then
install mounting pin (2) and lock it with the bolt.
a Take care that the cord ring will not be caught.
a Clearance (b): Max. 1.5 mm
[*3]
Adjust the lift arm angle sensor assembly. For details, see Test-
ing and adjusting, "Testing and adjusting lift arm position sensor
lever".
[*4]
Sling the assembly of the lift arm, bell crank and bucket link and
set it to the lift arm mounting hole of the front frame. Insert a
shim so that clearances (c) on the right and left sides will be the
same, and then install pin (15) and lock it with the bolt.
a Take care that the cord ring will not be caught.
a Clearance (c): Max. 1.0 mm
k After installing the pin, set a stand under the lift arm
end.
[*5]
Press fit the respective bushings to the bucket link, bell crank
and lift arm with puller [3] and install the dust seals.
2 Bushing: Grease (G2-LI)
a The figure shows the lift arm.
q Supply grease to each pin.
6 WA500-6
50 Disassembly and assembly SEN02031-02
WA500-6 7
SEN02031-02 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
6. Remove right and left battery box covers (6) and (7).
Tool: Socket wrench
Mounting bolt for covers (6), (7): Width across flats 17 mm,
M10
8 WA500-6
50 Disassembly and assembly SEN02031-02
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Socket wrench
Mounting bolt for cover (6), (7): Width across flats 46 mm, M30
3 Counterweight mounting bolt:
1,372 to 1,764 Nm {140 to 180 kgm}
WA500-6 9
SEN02031-02 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
1. Remove the right and left batteries and right and left battery
covers. For details, see "Removal and installation of large
counterweight assembly".
2. Sling counterweight assembly (2), remove its 4 mounting
bolts (1), and lift it off. [*1]
Tools: Belt sling, socket wrench
Mounting bolt for counterweight assembly (2): Width across
flats 36 mm, M24
4 Counterweight: 900 kg
10 WA500-6
50 Disassembly and assembly SEN02031-02
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Torque wrench (socket)
Mounting bolt for counterweight assembly (2): Width across flats
36 mm, M24
3 Mounting bolt for counterweight:
785 to 980 Nm {80 to 100 kgm}
WA500-6 11
SEN02031-02
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
12
SEN02032-05
WA500-6
WA500-6 1
SEN02032-05 50 Disassembly and assembly
2 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
k Set the lock bar to the frame, apply the parking brake, and lock the tires with chocks.
1. Remove floor skirt cover (1) and right and left covers (2).
Tool: Socket wrench
Cover (1), (2): Width across flats 14 mm, M10
2. Open the external air filter cover and remove filter (3) and
filter box (4).
Tool: Socket wrench
Mounting bolt for cover: Width across flats 17 mm, M10
WA500-6 3
SEN02032-05 50 Disassembly and assembly
5. Remove right and left covers (7) under the hydraulic tank.
Tool: Socket wrench
Mounting bolt for cover (7): Width across flats 19 mm, M12
4 WA500-6
50 Disassembly and assembly SEN02032-05
10. Remove air conditioner pipe and heater hose fixing plate
(12).
Tool: Socket wrench
Mounting bolt for plate (12): Width across flats 17 mm, M10
20. Remove right and left pillar covers (21) and (22).
Tool: Phillips screwdriver
Mounting screw for pillar covers (21), (22): M6
WA500-6 5
SEN02032-05 50 Disassembly and assembly
25. Remove right and left covers (30) and (31) on the front side
of the cab.
Tool: Phillips screwdriver
Mounting screw for monitor dashboard cover (29): M6
6 WA500-6
50 Disassembly and assembly SEN02032-05
33. Disconnect hose (42) of the cooler and heater hoses from
the air conditioner unit.
WA500-6 7
SEN02032-05 50 Disassembly and assembly
8 WA500-6
50 Disassembly and assembly SEN02032-05
Installation
q Carry out installation in the reverse order to removal.
[*1]
Tool: Socket wrench
Mounting bolt for cab (a mark) Width across flats 30 mm, M20
Mounting bolt for cab (● mark, ▲ mark) Width across flats 19
mm, M12
3 Cab mounting bolt: (M20): 490 to 608 Nm {52 to 62
kgm}
(M12): 98 to 123 Nm {10 to 12.5
kgm}
[*2]
Replace seal (46) between the operator's cab and floor frame.
1) Stick the seal along the periphery of the floor frame top.
2) Remove oil, grease, dust, etc. from the sticking sur-
face.
3) Do not cut the bent parts of the seal but stick them as
they are. Bend each part by 10 – 20 mm.
a If the operator's cab is not sealed perfectly, the
pressurizing performance of the cab lowers and
the noise in the operator's cab increases.
WA500-6 9
SEN02032-05 50 Disassembly and assembly
Removal and installation of operator's cab and floor frame assembly (cab-floor
unit specification) 1
10 WA500-6
50 Disassembly and assembly SEN02032-05
WA500-6 11
SEN02032-05 50 Disassembly and assembly
Removal
k Set the lock bar to the frame, apply the parking brake, and lock the tires with chocks.
k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic
tank.
k Operate the work equipment control lever 2 - 3 times to release the pressure in the PPC accumu-
lator circuit.
k Release residual pressure in brake accumulator circuit. For detail, see Testing and adjusting
"Releasing residual pressure in brake accumulator circuit".
k Disconnect the cable from the negative (–) terminal of the battery.
k In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant
temperature in the radiator is high, you may be scalded. In this case, wait until the coolant tem-
purature lowers and then disconnect the heater hose.
12 WA500-6
50 Disassembly and assembly SEN02032-05
WA500-6 13
SEN02032-05 50 Disassembly and assembly
14 WA500-6
50 Disassembly and assembly SEN02032-05
30. Lift off operator's cab and floor frame assembly (45).
Tool: 4-point chain, lever block
a Before removing the assembly, check that all the wiring
harnesses and pipings are disconnected.
4 Operator's cab and floor frame assembly: 1,200 kg
WA500-6 15
SEN02032-05 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
a Note the following points, when installing the air conditioner
circuit hoses.
q When installing the air conditioner circuit hoses, take
care that dirt, dust, water, etc. will not enter them.
q Before connecting each air conditioner hose, check
that the O-rings are fitted to its joints.
q Check that each O-ring is not damaged or deteriorated.
2 O-ring and threaded part: Compressor oil for R134a
(refrigerant piping: DENSO: ND-OIL8, Valeo thermal sys-
tems: ZXL100PG (PAG46 or equivalent)).
Tool: Torque wrench (open-end)
Air conditioning hose (8): Width across flats 27 mm, M24
Air conditioning hose (9): Width across flats 19 mm, M16
3 Threaded part of hose (M16 x 1.5):
12 to 15 Nm {1.2 to 1.5 kgm}
Threaded part of hose (M24 x 1.5):
30 to 35 Nm {3.0 to 3.5 kgm}
a Tighten each nut with 2 spanners.
q Fill the air conditioner circuit with refrigerant (air condi-
tioning gas: R134a).
a Quantity of the air conditioner gas: 1,250 ± 50 g
[*2]
Tool: Torque wrench (socket)
Nut (44): Width across flats 46 mm, M30
3 Floor frame mounting nut:
1,177 to 1,471 Nm {120 to 150 kgm}
q Bleeding air
Bleed air from the each part. For details, see Testing and
adjusting, "Bleeding air from brake circuit" and "Bleeding air
from steering cylinder circuit".
16 WA500-6
50 Disassembly and assembly SEN02032-05
a In this section, the procedure for replacing the stuck glass is explained.
WA500-6 17
SEN02032-05 50 Disassembly and assembly
18 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
a The operator's cab glasses of this machine are fully stuck with adhesive.
a Remove the window glass to be replaced according to the following procedure.
1. Using seal cutter [1], cut the adhesive between broken win-
dow glass (1) and operator's cab (2).
Tool: Seal cutter [1], fine wire [2], pliers [3]
WA500-6 19
SEN02032-05 50 Disassembly and assembly
Installation
1. Using scraper [5], remove the remaining adhesive from the
sticking surfaces.
Tool: Scraper [5]
a Do not scratch the paint.
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab
(2) and window glass (3) with white gasoline.
a If the sticking surfaces are not cleaned well, the glass
may not be stuck perfectly.
a Clean all the black part on the back side of the window
glass.
a After cleaning the sticking surfaces, leave them for at
least 5 minutes to dry.
20 WA500-6
50 Disassembly and assembly SEN02032-05
WA500-6 21
SEN02032-05 50 Disassembly and assembly
6. Apply primer.
a The using limit of primer (5) is 4 months after the date
of manufacture. Do not use the primer after this limit.
a Use the primer within 2 hours after unpacking it.
a Even if the primer is packed again just after it is
unpacked, use it within 24 hours after it is unpacked for
the first time. (Discard the primer 24 hours after it is
packed.)
1) Stir the primers for paint and glass sufficiently before
using them.
a If the primer has been stored in a refrigerator,
leave it at the room temperature for at least half a
day before stirring it. (If the primer is unpacked just
after taken out of the refrigerator, water will be con-
densed. Accordingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (6), wash it in white gaso-
line.
a After washing the brush, check it again for dirt and
foreign matter.
a Prepare respective brushes for the paint primer
glass primer.
22 WA500-6
50 Disassembly and assembly SEN02032-05
7. Apply adhesive.
a Use either of the 2 types of the adhesive, depending on
the season.
2 Adhesive (April – October):
SUNSTAR PENGUINE SEAL 580 SUPER "S"
2 Adhesive (October – April):
SUNSTAR PENGUINE SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months after the
date of manufacture. Do not use the adhesive after this
limit.
a Keep the adhesive in a dark place where the tempera-
ture is below 25 °C.
a Never heat the adhesive higher than 30 °C.
a When reusing the adhesive, remove the all hardened
part from the nozzle tip.
WA500-6 23
SEN02032-05 50 Disassembly and assembly
24 WA500-6
50 Disassembly and assembly SEN02032-05
2) Using tool X3, raise and place window glass (3) on tool
X2-1 (5-mm spacer) and stick it to the operator's cab.
Tool: X3 (suction disk)
a Match the lines of the match tapes stuck in step 1.
a Stick the glass within 10 minutes after applying the
adhesive.
a Before sticking the glass, check again that the
primer is applied to the glass sticking surface.
WA500-6 25
SEN02032-05 50 Disassembly and assembly
10. If the front glass and the right and left front glasses are
replaced, seal them.
1) Stick masking tapes (14) along the parts to be sealed
shown in the figure.
a Stick the masking tapes to both inside and outside
of the operator's cab.
11. Remove the primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhesive before it
dries.
a When cleaning the glass, do not give an impact to it.
26 WA500-6
50 Disassembly and assembly SEN02032-05
a Although the machine of the joystick steering specification is not equipped with the left armrest, its oper-
ator's seat assembly are also disassembled and assembled according to the following procedure.
I. Upper seat
1. Removal and installation of storage box
Removal
1) Open the storage box (1).
2) Remove the hook (3).
3) Undo the screws (2) and remove the storage box (1).
Installation
1) Set the storage box (1) and fix it with the screws (2).
2) Install the hook (3).
Removal
1) Remove the storage box by referring to "1. Removal
and installation of storage box".
2) Undo the 4 screws (1), and remove the backrest uphol-
stery (2).
3) Undo the 5 screws (4), and remove the seat pad (5).
4) Disconnect the connectors (3) and (6).
Installation
1) Connect the connectors (3) and (6).
2) Install the seat pad (5), and fix it with the 5 screws (4).
3) Install the backrest upholstery (2), and fix it with the 4
screws (1).
4) Install the storage box by referring to "1. Removal and
installation of storage box".
WA500-6 27
SEN02032-05 50 Disassembly and assembly
Removal
1) Remove the storage box by referring to "1. Removal
and installation of storage box".
2) Remove the backrest upholstery by referring to "2.
Removal and installation of seat pad and backrest
upholstery".
3) Drill off the rivets (1), loosen the spring steel sheets (2)
from the L-bar (3) and remove them.
4) Unhook the L-bars (3) from the catch element (4).
5) Undo the hexagon socket screw (5) and remove the
adjusting knob (6) with the toothed wheel (7).
6) Drill off the rivet (8), remove the wrap spring brake ele-
ment (9) and the catch element (4).
Installation
1) Install the wrap spring brake element (9) and the catch
element (4), and fix them with the rivets (8).
2) Install the adjusting knob (6) and the toothed wheel (7),
and tighten the hexagon socket screw (5).
3) Install the catch element (4) to the L-bars (3) and fix
with the rivets (1).
4) Install the 2 spring steel sheets (2) to the L-bar (3), and
fix with the rivets (1).
5) Install the backrest upholstery by referring to "2.
Removal and installation of seat pad and backrest
upholstery".
6) Install the storage box by referring to "1. Removal and
installation of storage box".
Removal
1) Remove the cover (1).
2) Unscrew the hexagon nuts (2) and remove the nuts
and washers (3).
3) Remove the armrests (4).
Installation
1) Set the armrests (4).
2) Put the washers (3) and tighten hexagon nuts (2).
Tool: Torque wrench (socket)
3 Hexagon nuts: 25 Nm {2.6 kgm}
3) Install the cover (1).
28 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Detach the storage box by referring to "1. Removal and
installation of storage box".
2) Remove the backrest upholstery by referring to "2.
Removal and installation of seat pad and backrest
upholstery".
3) Remove the armrests by referring to "4. Removal and
installation of armrests". (If equipped)
4) Disassemble the backrest adjustment by referring to "6.
Disassembly and assembly of backrest adjustment".
5) Unscrew the hexagon nut (5) and remove the washers
(6) and (7).
6) Remove the hexagon bolt (11) and the washer (10).
7) Press the backrest (1) slightly to the left and take it off
upwards.
8) Remove the bearing (8) and the torsion spring (9) from
the backrest (1).
Installation
1) Install the bearing (8) and the torsion spring (9) to the
backrest (1).
a Oil the bearing point (Q) on the backrest (1) for the
bearing (8) with acid-free multiple-purpose lubri-
cant.
a Insert the bearing (B/8) into the upper hole on the
backrest support on the right side (figure B/4).
WA500-6 29
SEN02032-05 50 Disassembly and assembly
2) Press the backrest (1) slightly to the left and install it.
a The big cylindrical stamping on the backrest
adjustment (figure C/2) must engage into the big
positional bore hole on the backrest support on the
left side (figure C/3).
a The integral catch on the backrest (figure A/1)
must engage into the torsion spring (figure A/9).
3) Put the washer (10) and tighten the hexagon bolt (11).
4) Put the washers (6) and (7), and tighten the hexagon
nut.
3 Hexagon nuts: 25 Nm {2.6 kgm}
5) Assemble the backrest adjustment by referring to "6.
Disassembly and assembly of backrest adjustment".
6) Install the armrests by referring to "4. Removal and
installation of armrests". (If equipped)
7) Install the backrest upholstery by referring to "2.
Removal and installation of seat pad and backrest
upholstery".
8) Install the storage box by referring to "1. Removal and
installation of storage box".
Disassembly
1) Remove the storage box by referring to "1. Removal
and installation of storage box".
2) Remove the backrest upholstery by referring to "2.
Removal and installation of seat pad and backrest
upholstery".
3) Remove the armrests by referring to "4. Removal and
installation of armrests". (If equipped)
4) Fold the backrest (1) forwards.
5) Unscrew 3 flat-headed screws (2), remove the adaptor
plate (3) and the flat-headed screw (4).
6) Remove the lever (5) and handle (6).
Assembly
1) Fold the backrest(1) forwards.
2) Install the handle (6) and the lever (5).
3) Tighten the 3 flat-headed screws (4), install the adaptor
plate (3) and then tighten the flat-headed screw (2).
a The lifter of the flat-headed screw (4) must engage
into the nut of the adaptor plate (3).
Tool: Torque wrench (socket)
3 Flat-headed screw: 12 Nm {1.2 kgm}
4) Install the armrests by referring to "4. Removal and
installation of armrests". (If equipped)
5) Install the backrest upholstery by referring to "2.
Removal and installation of seat pad and backrest
upholstery".
6) Install the storage box by referring to "1. Removal and
installation of storage box".
30 WA500-6
50 Disassembly and assembly SEN02032-05
Disassembly
1) Remove the seat pad by referring to "2. Removal and
installation of seat pad and backrest upholstery".
2) Remove the switch by the following procedure. (If
equipped)
1] Disconnect the spring (1).
2] Tilt the switch-plate (2) forwards and remove it.
3] Drill off the rivet (3) and remove the seat switch
(4).
3) Remove the flexible support plate (7) by the following
procedure.
1] Press the spring plate (5) ("P" position) inwards
(arrow), operate the lever for seat angle adjust-
ment (6).
2] Pull the flexible support plate (7) to backwards and
remove it.
4) Remove the plate (15) by the following procedure.
1] Drill off the rivet and remove the spring steel sheet
(5).
2] Unscrew the hexagon socket screws (8), remove
the cover (9), the levers for seat angle and seat
depth adjustment (6), (10), the linkage rod (11) and
the locking lever (12).
3] Remove the spring (13).
4] Turn the lever (14) clockwise until it snaps-in, pull
the plate (15) to the very front and remove it.
5) Remove the covers on the right and left side by refer-
ring to "8. Removal and installation of covers".
6) Unscrew the nut (16), remove the lever (14) and the
screw (17).
7) Drill off the rivet (18) and remove the spring steel
sheets (19).
8) Drill off the rivet (20) and remove the locating element
(21).
Assembly
1) Install the locating element (21) and fix it with the rivet
(20).
2) Install the spring steel sheets (19) and fix it with the
rivet (18).
3) Set the lever (14) and the screw (17), and fix with nut
(16).
4) Install the covers on the right and left side by referring
to "8. Removal and installation of covers".
5) Assemble the plate (15) by the following procedure.
1] Turn the lever (14) clockwise until it snaps-in,
install the plate (15).
2] Install the spring (13) to hook (a) of the lever (14)
and hook (b) of the plate (15).
3] Fix the locking lever (12), the linkage rod (11), the
levers (6), (10) and the cover (9) with the hexagon
socket screw (8).
4] Install the spring steel sheet (5) and fix it with the
rivet (22).
WA500-6 31
SEN02032-05 50 Disassembly and assembly
Removal
1) Remove the seat pad by referring to "2. Removal and
installation of seat pad and backrest upholstery".
2) Remove spring(1) and switch-plate (2). (If equipped)
3) Remove the flexible support plate by following proce-
dure.
1] Press the spring sheet inwards (arrow), operate
the lever for seat angle adjustment (3).
2] Pull the flexible support plate (4) to backwards and
remove it.
4) Remove the spring (5).
5) Turn the lever (6) clockwise until it snaps-in, pull the
plate (7) to the very front and remove it.
6) Drill off the rivet (8) and remove the washers (9).
7) Unhook the covers (10) by pulling them forwards and
remove them in an upward direction.
Installation
1) Install the covers (10) of right and left.
2) Install the washers (9) and fix it with the rivet (8).
3) Turn the lever (6) clockwise until it snaps-in, then install
the plate (7).
4) Remove the spring (5) (see 7. Disassembly and
assembly of seat angle and seat depth adjuster).
5) Install the flexible support plate (4) (see 7. Disassembly
and assembly of seat angle and seat depth adjuster).
6) Install spring (1) and switch-plate (2) (see 7. Disassem-
bly and assembly of seat angle and seat depth
adjuster). (If equipped)
7) Install the seat pad by referring to "2. Removal and
installation of seat pad and backrest upholstery".
32 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the seat pad by referring to "2. Removal and
installation of seat pad and backrest upholstery".
2) Push the seat top assembly (1) as far back as possible.
3) Unscrew the hexagon socket screws (2) and remove
the nuts (3).
4) Push the seat top assembly (1) as far forward as possi-
ble.
5) Unscrew the hexagon socket screws (4), remove the
washers (5) and nuts (6).
6) Remove the seat top assembly (1) and remove the
washers (7).
7) Disconnect the bellows from the upper part of the sus-
pension system and lay it down.
8) Unscrew the hexagon socket screws (8) and remove
the nuts (9).
9) Remove the slide rails (10).
Installation
1) Install the slide rails (10).
2) Put the nuts (9) and tighten the hexagon socket screws
(8).
a Replace the hexagon socket screws (8) with new
ones.
Tool: Torque wrench (socket)
3 Hexagon socket screws: 25 Nm {2.6 kgm}
3) Install the bellows to the upper part of the suspension
system.
4) Put the washers (7) and install the seat top assembly
(1).
5) Put the washers (5) and nuts (6), then tighten the hexa-
gon socket screws (4).
a Replace the hexagon socket screws (4) with new
ones.
3 Hexagon socket screws: 25 Nm {2.6 kgm}
6) Push the seat top assembly (1) as far forward as possi-
ble.
7) Put the nuts (3) and tighten the hexagon socket screws
(2).
a Replace the hexagon socket screws (2) with new
ones.
Tool: Torque wrench (socket)
3 Hexagon socket screws: 25 Nm {2.6 kgm}
8) Push the seat top assembly (1) as far back as possible.
9) Install the seat pad by referring to "2. Removal and
installation of seat pad and backrest upholstery".
WA500-6 33
SEN02032-05 50 Disassembly and assembly
II. Suspension
1. Removal and installation of top cover
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Pull the connecting cable (3) inwards through the upper
cover (2).
3) Remove the 2 bellows pins (1) and take the upper
cover (2) off.
Installation
1) Install the connecting cable (3) inwards through the
upper cover (2).
2) Install the upper cover (2) and fix it with the 2 bellows
pins (1).
3) Install the upper part of the seat by referring to "I.
Upper seat".
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Bore out 2 rivet heads and drive out blind rivets (1),
remove the front cover (2).
Installation
1) Install the front cover (2) and fix it with the 2 rivets (1).
2) Install the top cover by referring to "1. Removal and
installation of top cover".
3) Install the upper part of the seat by referring to "I.
Upper seat".
34 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the bellows (2) from the upper part of the sus-
pension (1) by following procedure.
1] Take bellows pins (4) off on the front.
2] Take bellows pins (3) off on the left side of the top.
3] Remove 2 bellows pins (4) on the back and take 2
bellows pins (3) off the upper part of the suspen-
sion system (1).
4] Take 3 bellows pins (3) on the right side off the
upper part of the suspension (1) and pull the bel-
lows (2) over the handle for vertical shock
absorber adjustment (9).
3) Remove the bellows (2) from the lower part of the sus-
pension (6) by the following procedure.
1] Take 3 bellows pins (3) on the front side off the
lower part of the suspension (6).
2] Release 2 bellows pins (3) on the left side from the
lower part of the suspension (6).
3] Release 4 bellows pins (3) on the back side from
the lower part of the suspension (6).
4] Remove a cable tie (10) on the right side from the
connecting cable, and take 2 bellows pins (3) off
the lower part of the suspension (6). (If equipped)
4) Lift the bellows (2) over the lower part of the suspen-
sion (6) and remove the bellows (2) in a downward
direction.
5) Remove the wire insert (5) from the bellows (2).
Installation
1) Install the wire insert (5) to the bellows (2).
2) Install the bellows (2).
3) Fix the bellows (2) with pins (3) to the lower part of the
suspension (6) in the reverse order of their removal.
4) Fix the connecting cable with the cable tie (10). (If
equipped)
5) Fix the bellows (2) with pins (3) to the upper part of the
suspension (1) in the reverse order of their removal.
6) Install the upper part of the seat by referring to "I.
Upper seat".
WA500-6 35
SEN02032-05 50 Disassembly and assembly
4. Removal and installation of Bowden pull wire and handle for vertical shock absorber adjustment
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower
part of the suspension system with suitable
spacers.
5) Screw out Torx screw (2).
6) Pull the handle for vertical shock absorber adjustment
(1) off the upper part of the suspension (4).
7) Remove the Bowden pull wire (5) from the handle for
vertical shock absorber adjustment (1).
8) Push the Bowden pull wire (5) off the bearing for
Bowden pull wire (6).
9) Bore out the rivet head and drive out the blind rivet (7),
and remove the bearing for Bowden pull wire (6).
10) Mark the points where the Bowden pull wire (5) is fas-
tened with the swinging structure (14) with the cable tie
(8) and take the cable tie (8) off.
11) Pull the fixation (12) off the vertical shock absorber
(13).
12) Take the Bowden pull wire (5) off the bearing (9).
13) Remove the fixation (12) from the fork (11).
36 WA500-6
50 Disassembly and assembly SEN02032-05
14) Take the Bowden pull wire (5) off the fork (11), remove
the fork (11) and compression spring (10).
15) Mark the location of the mounting hole for the Bowden
pull wire (5) in the upper part of the suspension (4), pull
the Bowden pull wire (5) out of the upper part of the
suspension (4) and then remove it.
Installation
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
2) Put the Bowden pull wire (5) to the upper part of the
suspension (4) through the location of the mounting
hole marked before removing the Bowden pull wire (5).
3) Install the fork (11) and compression spring (10), and
take the Bowden pull wire (5) to the fork (11).
4) Install the fixation (12) to the fork (11).
5) Take the Bowden pull wire (5) to the bearing (9).
6) Put the fixation (12) to the vertical shock absorber (13).
7) Install the Bowden pull wire (5) and fix it with the cable
tie (8) at the marked points.
a Install the Bowden pull wire according to the mark-
ing.
8) Install the bearing for Bowden pull wire (6) and fix it
with the rivet (7).
9) Install the Bowden pull wire (5) to the bearing for
Bowden pull wire (6).
10) Install the Bowden pull wire (5) to the handle for vertical
shock absorber adjustment (1).
11) Install the handle for vertical shock absorber adjust-
ment (1) to the upper part of the suspension (4).
12) Tighten Torx screw (2).
Tool: Torque wrench (socket)
3 Torx screw: 2.25 Nm {0.23 kgm}
13) Install the bellows off by referring to "3. Removal and
installation of bellows".
14) Install the top cover by referring to "1. Removal and
installation of top cover".
15) Install the upper part of the seat by referring to "I.
Upper seat".
WA500-6 37
SEN02032-05 50 Disassembly and assembly
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
5) Remove circlip (8) from stud (6).
6) Pull the stud (6) out of swinging structure (7) and verti-
cal shock absorber (4).
7) Take the fixation (2) and bearing (1) off the vertical
shock absorber (4).
8) Remove circlip (5) from stud (3).
9) Pull the stud (3) out of the swinging structure (7) and
the vertical shock absorber (4).
10) Remove the vertical shock absorber (4) in an upward
direction.
Installation
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
2) Install the vertical shock absorber (4).
a When re-installing the vertical shock absorber (4),
make sure the labeling is on top.
3) Assemble the vertical shock absorber (4) to the swing-
ing structure (7) and put the stud (3).
4) Install circlip (5) to the stud (3).
a Apply acid-free multi-purpose lubricant to the
entire external surface (F) of the stud (3).
5) Install the fixation (2) and bearing (1) to the vertical
shock absorber (4).
6) Assemble the vertical shock absorber (4) to the swing-
ing structure (7) and put the stud (6).
a Apply acid-free multi-purpose lubricant to the
entire external surface (F) of the stud (6).
7) Install the circlip (8) to the stud (6).
8) Install the bellows by referring to "3. Removal and
installation of bellows".
9) Install the top cover by referring to "1. Removal and
installation of top cover".
10) Install the upper part of the seat by referring to "I.
Upper seat".
38 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
5) Mark the points where the compressor cable (5) is fas-
tened with the 6 cable ties (6) and remove the cable
ties (6).
6) Disconnect the right-angle plug (10) from the height
level control unit (1).
7) Disconnect the electric connector of the flat plug (11).
8) Mark the points where the compressed-air hose (7) is
fastened with the cable tie (12) and remove the cable
tie (12).
9) Mark the points where the compressor (3) is fastened
with the 2 cable ties (4) and remove the cable ties (4).
10) Pull the fitting (8) out of the spike of the compressor (3)
and push it backwards off the compressed-air hose (7).
11) Pull the compressed-air hose (7) off the compressor
(3).
a Do not use a screwdriver to lift the compressed-air
hose (7) off the spike of the compressor (3).
WA500-6 39
SEN02032-05 50 Disassembly and assembly
Installation
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
2) Install the support (9) to the lower part of the suspen-
sion (2).
3) Install the compressor (3) to the support (9).
4) Install the compressed-air hose (7) and fix it with cable
tie (4) at the marked points.
a Loosely apply the cable tie (4) until the locking
head of the cable tie (4) is located slightly over the
front curve of compressor (3) and while the com-
pressor (3) can be still moved.
a Align the compressor (3) and use the pliers to
tighten the locking head of the cable tie (4) to 310
Nm{31.6 kgm} in the direction shown (arrow).
5) Put the fitting (8) to the compressed-air hose (7).
6) Install them to the spike of the compressor (3).
7) Fix the compressor (3) with the cable ties (4) at marked
points.
a Fix the cable tie according to the marking.
8) Fix the compressed-air hose (7) with cable tie (12) at
the marked points.
9) Connect the electric connector of the flat plug (11).
10) Connect the right-angle plug (10) to the height level
control unit (1).
11) Install the compressor cable (5) and fix it with cable tie
(6) at the marked points.
a Tie back any excess length of the compressor
cable (5).
12) Install the bellows off by referring to "3. Removal and
installation of bellows".
13) Install the top cover by referring to "1. Removal and
installation of top cover".
14) Install the upper part of the seat by referring to "I.
Upper seat".
40 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
5) Loosen up the 2 circlips (17) from the stud (18) and
then remove them.
6) Knock out the stud (18) from the lower part of the sus-
pension (15) and then remove it.
a Firmly hold the webbing (5) and let it carefully roll
back to the rewinder on the height level controller
(1).
7) Remove the 2 buffers (16) from the loop of the webbing
(5).
8) Mark the points where the air input hoses (10) and (11)
are fastened with 5 cable ties (12) and remove the
cable ties (12).
9) Pull the air input hoses (10) and (11) off the pneumatic
spring (see "8. Removal and installation of air hose").
10) Mark the place where the cable is fastened with the
right-angle plugs (13) and (14) and the cable tie and
then remove the cable tie.
WA500-6 41
SEN02032-05 50 Disassembly and assembly
11) Mark the place where the Bowden pull wire (19) is fas-
tened with the cable tie and remove the cable tie.
12) Unhook the Bowden pull wires (3) and (19) from the
height level control (1).
13) Mark and then disconnect the right-angle plugs (13)
and (14) from the height level control unit (1).
14) Remove the 2 hexagon nuts (4) from the thread of the
height level control (1).
15) Remove the plate (7), loop of the webbing (5) and the
edge protection strip (6).
16) Remove the height level control (1) from the upper part
of the suspension (8).
17) Undo the Torx screw (9) and take the attachment for
Bowden pull wire (2) off the height level valve (1).
a To do this, first release the 2 catchers on the back-
side of the attachment for Bowden pull wire (2) and
take the attachment for Bowden pull wire (2) off the
height level valve (1).
18) Pull the Bowden pull wire (3) out of the attachment for
Bowden pull wire (2).
19) Remove the height level controller in an upward direc-
tion.
Installation
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
2) Install the height level controller.
3) Install the Bowden pull wire (3) to the attachment for
Bowden pull wire (2).
4) Install the attachment for Bowden pull wire (2) to the
height level controller (1).
5) Tighten the Torx screw (9) to height level controller (1).
a Finger-tighten the Torx screw (9).
6) Install the height level control (1) to the upper part of
the suspension (8).
7) Install the plate (7), loop of the webbing (5) and the
edge protection strip (6).
8) Install the 2 hexagon nuts (4) to the thread of the height
level controller (1).
9) Connect the right-angle plugs (13) and (14) to the
height level controller (1) at the marked point.
10) Install the Bowden pull wires (3) and (19) to the height
level controller (1).
11) Install the Bowden pull wire (19) and fix it with the cable
tie at the marked points.
12) Install the right-angle plugs (13) and (14) and fix them
with the cable tie at the marked points.
13) Install the air input hoses (10) and (11) to the pneu-
matic spring (see "8. Removal and installation of air
hose").
14) Fix the air input hoses (10) and (11) with the 5 cable
ties (12) at the marked points.
15) Install the 2 buffers (16) to the loop of the webbing (5).
16) Install the stud (18) to the lower part of the suspension
(15).
42 WA500-6
50 Disassembly and assembly SEN02032-05
17) Install the 2 circlips (17) to the stud (18) and then
remove them.
18) Install the bellows by referring to "3. Removal and
installation of bellows".
19) Install the top cover by referring to "1. Removal and
installation of top cover".
20) Install the upper part of the seat by referring to "I.
Upper seat".
Adjustment
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
5) Loosen the self-tapping screw (9) a half turn.
6) Adjust the micro-switch (3) as follows.
Adjust the clearance between cam switch (5) and cam
disc (7) by turning the cross-head screw (8).
q Specified clearance (A) = 0.5 mm.
q Turn the cross-head screw (8) to the left, the cam
switch (5) is moving towards the cam disc (7).
q Turn the cross-head screw (8) to the right, the cam
switch (5) is moving away from the cam disc (7).
WA500-6 43
SEN02032-05 50 Disassembly and assembly
q When the cam switch (5) seats on the cam disc (7)
under pressure, the compressor (11) turns too early
and runs already during the compression and
expansion of the seat suspension.
7) Adjust the output level (2) as follows.
Adjust the clearance between valve lever (6) and cam
disc (7) by turning the cross-head screw (10).
q Specified value: The valve lever (6) must seat on
the cam disc without pressure (7).
q Turn the cross-head screw (10) to the left, the
valve lever (6) is moving towards the cam disc (7).
This increases the pressure on the valve tappets
(4) at the output valve (2) and the air escapes the
output valve (2) earlier.
q Turn the cross-head screw (10) to the right, the
valve lever (6) is moving away from the cam disc
(7). This decreases the pressure on the valve tap-
pets (4) at the output valve (2) and the air escapes
the output valve (2) later.
8) Tighten the self-tapping screw (9) after the adjustment
has been completed.
9) Install the bellows off by referring to "3. Removal and
installation of bellows".
10) Install the top cover by referring to "1. Removal and
installation of top cover".
11) Install the upper part of the seat by referring to "I.
Upper seat".
44 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
5) Mark the points where the compressed-air hose (11) is
fastened with the cable tie (12) and remove the cable
tie (12).
6) Pull the compressed-air hose (11) off the pneumatic
spring (9).
a When pulling the hoses out, the retaining ring of
the quick coupling (13) must first be completely
pressed back (e.g. using a flat pliers) to avoid
marks.
7) Pull the compressed-air hose (11) off the compressor
(5) and remove it. (Refer to "6. Removal and installa-
tion of compressor")
8) Pull the compressed-air hose with angle (8) off the
pneumatic spring (9) and then off the air tank (10).
WA500-6 45
SEN02032-05 50 Disassembly and assembly
46 WA500-6
50 Disassembly and assembly SEN02032-05
Installation
a Always replace a damaged (marks) hose with a new one. It
is possible to cut the damaged part off (about 12 mm) using
special tools (14) only once. After the cut off, the blue mark-
ing should be (arrow) set back by the length of the cut off
piece.
Hydrostatic test
a After the installation of a compressed-air hose, the hydraulic
test of the suspension should be performed.
q Apply 60 kg load to the suspension for 24 hours.
q The lowering within this time may not exceed 15 mm.
a The compressed-air hoses are locked after they have been
connected.
WA500-6 47
SEN02032-05 50 Disassembly and assembly
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Mark the points where the Bowden pull wire (1) is fas-
tened with the 2 cable ties (3), and then remove the
cable ties (3).
5) Mark the points where the Bowden pull wire (6) is fas-
tened with the 2 cable ties (8), and then remove the
cable ties (8).
6) Take the Bowden pull wire (1) off the height level con-
troller and pull it out of the holder for Bowden pull wire
(See "7. Removal and installation of height level con-
troller".)
a To release the tension of the Bowden pull wire (1),
press the handle for height adjustment (5)
upwards.
7) Take the Bowden pull wire (6) off the height level con-
troller. (See "7. Removal and installation of height level
controller")
a To release the tension of the Bowden pull wire (6),
press the handle for height adjustment (5)
upwards.
8) Undo the 3 cross-head screws (7).
9) Take the Bowden pull wires (1) and (6) off the holder for
Bowden pull wire (4), and then pull them out of the
upper part of the suspension (2).
10) Remove the holder (4) for Bowden pull wire.
11) Replace the handle (5), if required.
a The handle (5) and holder for Bowden pull wire (4)
are wedged into the 2 latching noses (arrow) at the
lower part of the holder for Bowden pull wire (4).
Carefully separate the parts.
a To remove the handle, use a screwdriver to bend
open the handle (5) between the handle (5) and
holder for Bowden pull wire (4) so that the 2 latch-
ing noses are released from the handle (5).
a Take the handle (5) off the holder for Bowden pull
wire (4).
Installation
1) Install the handle (5) to holder (4), if removed.
a When the handle (5) is deformed, replace it.
2) Install the Bowden pull wires (1) and (6) to the holder
for Bowden wire (4).
a Adjust the new Bowden pull wire to the length of
the old one (excess length of the wire).
3) Install the holder (4) to the upper part of the suspension
(2) and tighten the 3 cross-head screws (7).
4) Install the Bowden pull wire (6) to the height level con-
troller. (See "7. Removal and installation of height level
controller".)
48 WA500-6
50 Disassembly and assembly SEN02032-05
5) Install the Bowden pull wire (1) to the height level con-
troller (See "7. Removal and installation of height level
controller".)
6) Fix the Bowden pull wire (6) with the 2 cable ties (8) at
the marked points.
a Loosely fix the Bowden pull wire with the cable ties
at the marked points and make sure it is not dis-
torted.
7) Fix the Bowden pull wire (1) with the 2 cable ties (3) at
the marked points.
a Loosely fix the Bowden pull wire with the cable ties
at the marked points and make sure it is not dis-
torted.
8) Install the bellows by referring to "3. Removal and
installation of bellows".
9) Install the top cover by referring to "1. Removal and
installation of top cover".
10) Install the upper part of the seat by referring to "I.
Upper seat".
WA500-6 49
SEN02032-05 50 Disassembly and assembly
Adjustment
1) Adjustment of the Bowden pull wire (3):
1] Loosen the counternut (6) and adjust the clear-
ance between the Bowden wire lever (10) and
holder for Bowden wire end cap (9) using the lock-
nut (5).
q Turn the locknut (5) inwards, the Bowden pull
wire gets longer.
q Turn the locknut (5) outwards, the Bowden
pull wire gets shorter.
q Specified value: Clearance (A) between 1 and
3.5 mm.
2] Secure the locknut (5) with the counternut (6) and
make sure not to distort the Bowden pull wire (3).
3] Operate the handle for seat height adjustment (2)
several times and check the specified value,
repeat the adjustment if necessary.
2) Adjustment of the Bowden pull wire (1):
1] Loosen the counternut (7) and adjust the tension
of the Bowden pull wire (1) on the height valve (4)
using the locknut (8).
q Turn the locknut (8) inwards, the Bowden pull
wire gets longer.
q Turn the locknut (8) outwards, the Bowden
pull wire gets shorter.
q Specified value: The Bowden wire (8) must be
tightened, but not distorted on the suspension
device on the height level valve (4).
2] Secure the locknut (8) with the counternut (7) and
make sure not to distort the Bowden pull wire (1).
3] Operate the handle for seat height adjustment (2)
several times and check the specified value,
repeat the adjustment if necessary.
50 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Remove the 2 air input hoses, compressed-air hose
and air input hose with angle from the pneumatic spring
(6) by referring to "8. Removal and installation of com-
pressed-air hoses".
5) Undo the counter sunk screw (3) from the pneumatic
spring (6) and remove it together with the washer (4).
6) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
7) Turn the spring system by 180 ° and place it onto the
upper part (1).
8) Undo the counter sunk screw (7) from the pneumatic
spring (6).
9) Slightly compress the pneumatic spring (6) and remove
it from the swinging structure (5) and lower part of the
suspension (2).
Installation
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
WA500-6 51
SEN02032-05 50 Disassembly and assembly
52 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
5) Remove the air hose with angle (4) from the air tank (3)
by referring to "8. Removal and installation of com-
pressed-air hoses".
6) Remove the air tank (3) from bracket (2) and clamp (5).
7) Take the clamp (5) off the bracket (6) in a downward
direction, if required.
a To do this, use a screwdriver to press through the
hole (arrow) in the bracket against the catchers
(arrow) of the clamp (5) and pull the clamp (5) out
in a downward direction.
Installation
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
2) Install the clamp (5) to the bracket (6), if removed.
a Replace the clamp with new one, if required.
3) Install the air tank (3) to bracket (2) and clamp (5).
4) Install the air hose with angle (4) to the air tank (3) by
referring to "8. Removal and installation of com-
pressed-air hoses".
5) Install the bellows by referring to "3. Removal and
installation of bellows".
6) Install the top cover by referring to "1. Removal and
installation of top cover".
7) Install the upper part of the seat by referring to "I.
Upper seat".
WA500-6 53
SEN02032-05 50 Disassembly and assembly
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
5) Mark the points where the cable of the machine power
connector (3) is fastened with the cable tie (8) on the
upper part of the suspension (7) and remove the cable
tie (8).
6) Mark places where the cable harness of the connector
plug (2) and cable harness of the machine power con-
nector (3) are fastened with the cable ties (5) and
remove the cable ties (5).
7) Disconnect the electric connection (flat plug) of the
compressor cable (4) to the cable harness of the con-
nector plug (2) and cable harness of the machine
power connector (3).
8) Disconnect the right-angle plug (6) from the height level
control unit (1).
54 WA500-6
50 Disassembly and assembly SEN02032-05
Installation
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
2) Connect the right-angle plug (6) to the height level con-
trol unit (1).
3) Connect the electric connection (flat plug) of the com-
pressor cable (4) to the cable harness of the connector
plug (2) and cable harness of the machine power con-
nector (3).
4) Fix the cable harness of the connector plug (2) and
cable harness of the machine power connector (3) with
the cable ties (5) at the marked points.
a Run the cable harnesses (2) and (3) and fix them
with the cable ties (5) so that they are neither
squeezed nor otherwise damaged.
5) Fix the cable of the machine power connector (3) with
the cable tie (8) on the upper part of the suspension (7)
at the marked points.
6) Install the bellows by referring to "3. Removal and
installation of bellows".
7) Install the top cover by referring to "1. Removal and
installation of top cover".
8) Install the upper part of the seat by referring to "I.
Upper seat".
WA500-6 55
SEN02032-05 50 Disassembly and assembly
Disassembly
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Take the Bowden pull wire and handle off the upper
part of the suspension (1) by referring to "4. Removal
and installation of Bowden pull wires and handle for
vertical shock absorber".
a The Bowden pull wire does not need to be taken
off the vertical shock absorber.
5) Remove the vertical shock absorber from the upper
part of the suspension (1) by referring to "5. Removal
and installation of vertical shock absorber".
6) Remove the height level controller from the upper part
of the suspension (1) by referring to "7. Removal and
installation of height level controller".
a Air input hoses do not need to be taken off the
pneumatic spring.
7) Remove Bowden pull wires and handle for height
adjustment by referring to "9. Removal and installation
of Bowden pull wires and handle for height adjust-
ment".
8) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure (7) and lower
part of the suspension system with suitable
spacers.
9) Bore out 2 rivet heads and drive out blind rivets (10),
remove the stops (9).
10) Push the upper part of the suspension (1) forwards until
the cut-outs (arrow) on the left and right sides at the
guiding rails (2) are located at the same height with the
front rollers (8) of the swinging structure (7).
11) Remove the upper part of the suspension (1) on the
front side over the rollers (8) and the back rollers (6) of
the swinging structure (7).
Assembly
1) Move the suspension system to the highest position.
k Risk of crushing! Secure the suspension
between the swinging structure and lower part
of the suspension system with suitable spac-
ers.
2) Push the upper part of the suspension (1) forwards until
the cut-outs (arrow) on the left and right sides at the
guiding rails (2) are located at the same height with the
front rollers (8) of the swinging structure (7).
3) Install the upper part of the suspension (1) on the back
rollers (6) and the front rollers (8) of the swinging struc-
ture (7).
a Apply acid-free multi-purpose lubricant to the side
surfaces (F) of the 2 guiding rails (2) of the rollers
(6).
4) Install the stops (9) and fix with the 2 rivets (10).
56 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
WA500-6 57
SEN02032-05 50 Disassembly and assembly
Installation
1) Install the upper part of the suspension (1) with the
swinging structure (3) together with the 2 rollers (2) to
the guiding rails (8).
a Apply acid-free multi-purpose lubricant to the bear-
ing surface at the side (F) of the 2 guiding rails (8)
of the rollers (2).
2) Install the U-shaped profile (6) to the guiding rail (8)
and tighten the 2 corrugated-head screws (5).
3) Put the counter sunk screws (9) and the washers (10),
and tighten the 2 hexagon nuts (11).
4) Install the 2 cable ties for the machine power connector
cable on the lower part of suspension(7) by referring to
"12. Removal and installation of cable harness".
5) Tighten the counter sunk screw to the pneumatic spring
by referring to "10. Removal and installation of pneu-
matic spring".
6) Install the webbing to the lower part of the suspension
(7) by referring to "7. Removal and installation of height
level controller".
7) Install compressor to the lower part of the suspension (7)
by referring to "6. Removal and installation of compressor".
8) Install the bellows by referring to "3. Removal and
installation of bellows".
9) Install the top cover by referring to "1. Removal and
installation of top cover".
10) Install the upper part of the seat by referring to "I.
Upper seat".
58 WA500-6
50 Disassembly and assembly SEN02032-05
Removal
1) Remove the upper part of the seat by referring to "I.
Upper seat".
2) Remove the top cover by referring to "1. Removal and
installation of top cover".
3) Take the bellows off by referring to "3. Removal and
installation of bellows".
4) Take the Bowden pull wire for vertical shock absorber
adjustment off the vertical shock absorber by referring
to "4. Removal and installation of Bowden pull wire and
handle for vertival shock absorber adjustment".
5) Take the vertical shock absorber off the swinging struc-
ture by referring to "5. Removal and installation of verti-
cal shock absorber".
6) Remove the compressor by referring to "6. Removal
and installation of compressor".
7) Take the webbing off the lower part of the suspension
by referring to "7. Removal and installation of height
level controller".
8) Remove the cable tie for the air input hoses of the
height level control and pull the air input hoses off the
pneumatic spring by referring to "8. Removal and
installation of compressed-air hoses".
9) Take the Bowden pull wires for height level adjustment
off the height level valve by referring to "9. Removal
and installation of Bowden pull wire and handle for
height adjustment".
10) Remove the pneumatic spring by referring to "10.
Removal and installation of pneumatic spring".
WA500-6 59
SEN02032-05 50 Disassembly and assembly
11) Remove the air tank for additional air supply by refer-
ring to "11. Removal and installation of air tank for addi-
tional air supply".
12) Remove the cable harness by referring to "12.
Removal and installation of cable harness".
13) Take the upper part of the suspension off the swinging
structure by referring to "13. Removal and installation
of upper part of the suspension".
14) Take the lower part of the suspension off the swinging
structure by referring to "14. Removal and installation
of lower part of the suspension".
15) Take 4 rollers (5), 2 rollers (6), 2 fixed bearings (9) and
4 felt rings (4) off the swinging structure (1).
16) Pull the tube piece (8) out of the fixed bearing (9).
17) Remove the 2 buffers (7) from the swinging structure
(1).
18) Remove the edge protection strip (2) from the swinging
structure (1).
Installation
1) Check: maximum clearance (A) or (B) between the roll-
ers (5) and guiding rails of the lower part of the suspen-
sion (11) or upper part of the suspension (10) over the
complete adjustment length.
2) Place the washer compensating for clearance (2)
between the roller (5 or 6) and axle of the swinging
structure (1), if necessary.
a Clearance spacers (with thickness of 0.2 mm and
0.5 mm) are included in the wear parts set.
3) Install the edge protection strip (2) to the swinging
structure (1).
4) Install the 2 buffers (7) to the swinging structure (1).
5) Put the tube piece (8) to the fixed bearing (9).
6) Install 4 rollers (5), 2 rollers (6), 2 fixed bearings (9) and
4 felt rings (4) to the swinging structure (1).
7) Install the lower part of the suspension to the swinging
structure by referring to "14. Removal and installation
of lower part of the suspension".
8) Install the upper part of the suspension to the swinging
structure by referring to "13. Removal and installation
of upper part of the suspension".
9) Install the cable harness by referring to "12. Removal
and installation of cable harness".
10) Install the air tank for additional air supply by referring
to "11. Removal and installation of air tank for additional
air supply".
11) Install the pneumatic spring by referring to "10.
Removal and installation of pneumatic spring".
12) Install the Bowden pull wires for height level adjustment
to the height level valve by referring to "9. Removal and
installation of Bowden pull wire and handle for height
adjustment".
13) Install the cable tie for the air input hoses of the height
level controller and pull the air input hoses to the pneu-
matic spring by referring to "8. Removal and installation
of compressed-air hoses".
60 WA500-6
50 Disassembly and assembly SEN02032-05
WA500-6 61
SEN02032-05 50 Disassembly and assembly
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
62 WA500-6
SEN02033-04
WA500-6
Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission controller assembly........................................................................ 4
Removal and installation of work equipment controller assembly .................................................................. 7
Removal and installation of KOMTRAX terminal assembly .......................................................................... 10
Removal and installation of air conditioner unit assembly .............................................................................11
WA500-6 1
SEN02033-04 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
2 WA500-6
50 Disassembly and assembly SEN02033-04
Installation
q Carry out installation in the reverse order to removal.
[*1]
a When installing each heavy duty wire connector, check that
it is locked.
3 Connectors (2) and (3): 2.54 to 3.01 Nm {0.26 to 0.32
kgm}
WA500-6 3
SEN02033-04 50 Disassembly and assembly
4 WA500-6
50 Disassembly and assembly SEN02033-04
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
WA500-6 5
SEN02033-04 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
a Before connecting each connector, check that its inside is
free from dirt, dust and water.
a When installing each heavy duty wire connector, check that
it is locked. (When it is locked, it clicks.)
3 Connectors (3), (4) and (5):
2.54 to 3.01 Nm {0.26 to 0.32 kgm}
6 WA500-6
50 Disassembly and assembly SEN02033-04
WA500-6 7
SEN02033-04 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of the battery.
8 WA500-6
50 Disassembly and assembly SEN02033-04
Installation
q Carry out installation in the reverse order to removal.
[*1]
a Before connecting each connector, check that its inside is
free from dirt, dust and water.
a When installing each heavy duty wire connector, check that
it is locked. (When it is locked, it clicks.)
3 Connectors (3), (4) and (5):
2.54 to 3.01 Nm {0.26 to 0.32 kgm}
WA500-6 9
SEN02033-04 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative (–) terminal of battery.
Installation
q Carry out installation in the reverse order to removal.
10 WA500-6
50 Disassembly and assembly SEN02033-04
WA500-6 11
SEN02033-04 50 Disassembly and assembly
Removal
k Set the lock bar to the frame, apply the parking brake, and lock the tires with chocks.
k Disconnect the cable from the negative (–) terminal of the battery.
k In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant
temperature in the radiator is high, you may be scalded. In this case, wait until the coolant tem-
purature lowers and then disconnect the heater hose.
12 WA500-6
50 Disassembly and assembly SEN02033-04
WA500-6 13
SEN02033-04 50 Disassembly and assembly
22. Disconnect air conditioner pipes (29) and (30) and clamp
bolts (31) and (32). [*1]
Tool: Socket wrench
Mounting bolt for air conditioner pipes (29), (30): Width
across flats 10 mm, M6
Clamp bolts (31), (32): Width across flats 10 mm, M6
14 WA500-6
50 Disassembly and assembly SEN02033-04
WA500-6 15
SEN02033-04 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to removal.
[*1]
a Note the following points, when installing the air conditioner
circuit hoses.
q When installing the air conditioner circuit hoses, take
care that dirt, dust, water, etc. will not enter them.
q Before connecting each air conditioner hose, check
that the O-rings are fitted to its joints.
q Check that each O-ring is not damaged or deteriorated.
2 O-ring and threaded part: Compressor oil for R134a
(refrigerant piping: DENSO: ND-OIL8, Valeo thermal sys-
tems: ZXL100PG (PAG46 or equivalent)).
3 Threaded part of hose (M16 x 1.5):
12 to 15 Nm {1.2 to 1.5 kgm}
Threaded part of hose (M24 x 1.5):
30 to 35 Nm {3.0 to 3.5 kgm}
a Tighten each nut with 2 spanners.
q Fill the air conditioner circuit with refrigerant (air condi-
tioning gas: R134a).
a Quantity of the air conditioner gas: 1,250 ± 50 g
[*2]
Tool: Torque wrench (socket)
Mounting bolt for air conditioner unit assembly (39): Width
across flats 13 mm, M8
3 Air conditioner unit mounting bolt:
8 to 12 Nm {0.81 to 1.22 kgm}
16 WA500-6
50 Disassembly and assembly SEN02033-04
WA500-6 17
SEN02033-04 50 Disassembly and assembly
© 2020 KOMATSU
All Rights Reserved
Printed in Japan 03-20 (01)
18 WA500-6
SEN06710-00
WA500-6
80 Appendix 1
Air conditioner
Precautions for refrigerant .............................................................................................................................. 3
Troubleshooting procedure ............................................................................................................................. 4
Circuit diagram and arrangement of connector pins ....................................................................................... 6
System diagram .............................................................................................................................................11
Detail of air conditioner unit .......................................................................................................................... 13
Parts and connectors layout ......................................................................................................................... 15
Testing with self-diagnosis function (indication on control panel) ................................................................. 19
Testing temperature control .......................................................................................................................... 22
Testing vent (mode) changeover................................................................................................................... 23
Testing Fresh/Recirc changeover ................................................................................................................. 25
Testing inside air temp. sensor and outside air temp. sensor ....................................................................... 27
Testing evaporator temperature sensor ........................................................................................................ 29
Testing sunlight sensor ................................................................................................................................. 30
Testing relays ................................................................................................................................................ 31
Troubleshooting chart 1 ................................................................................................................................ 32
Troubleshooting chart 2 ................................................................................................................................ 33
Information in troubleshooting table .............................................................................................................. 36
Troubleshooting for power supply system (Air conditioner does not operate) .............................................. 37
Troubleshooting for compressor and refrigerant system (Air is not cooled).................................................. 40
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .................................. 43
Troubleshooting for temperature control ....................................................................................................... 49
Troubleshooting for vent (mode) changeover ............................................................................................... 52
Troubleshooting for Fresh/Recirc air changeover ......................................................................................... 55
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Troubleshooting procedure 1
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function,
you can inspect the operation of sensor and actuators in the system.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Find the troubled section with the self-diagnosis function (See "Inspection with self-diagnosis").
If the air conditioner unit or control panel does not operate at all, check that the power supplied to the
control panel is normal.
If any part of the air conditioner unit or control panel operates, the power supply does not need to be
checked.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic flow of troubleshooting
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*1: By LCD blink on air conditioner control panel (Failure code may be displaied on the temperature display
area in the case of auto air conditioner.)
*2: Simple checking of refrigerant volume by sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the con-
dition is normal.
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit
will definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting nd connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
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System diagram 1
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1. Evaporator
2. Evaporator temperature sensor
3. Sensor holder
4. Heater core
5. Pressure switch
6. Fuse
AMA: Air mix actuator
BR: Blower off relay
BA: Blower amplifier
CR: Compressor relay
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1. Evaporator
2. Evaporator temperature sensor
3. Sensor holder
4. Heater core
5. Pressure switch
6. Fuse
AMA: Air mix actuator
BR: Blower off relay
BA: Blower amplifier
CR: Compressor relay
MA: Mode actuator
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a Fuses are installed at two places in the air con- 4. Machine wiring harness connectors C49, C50
ditioner unit (wiring harness) and in the fuse and AL1 are on the left of the air conditioner
box at the left rear of the operator's seat (dupli- unit.
cated). q [3] – [8] are symbols in the circuit diagram.
1. Open the fuse box cover at the left rear of the
operator's seat. (See the fuse locations in
Troubleshooting.)
q No. 10 of fuse box A: 20A
For power supply of blower (fan) and air
conditioner unit
q No. 11 of fuse box A: 5A
For air conditioner compressor
q Fuse part Nos.
5A: 08041-00500
20A:08041-02000
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7. Take out filter (4) and remove box (5). a Connector FL1 is DRC-70 and must be
handled with care.
q How to disconnect connector FL1
Disconnect the connector straight slowly
and check the seal for breakage, peeling
and sticking foreign matter.
a If the seal is damaged, replace it.
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1. Remove cover (1). 5. Turn the starting switch ON and then turn the
q A/C U: Air conditioner unit power of the air conditioner ON.
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a Auto air conditioner equipped only. 2. Check contacts of connectors C47, C50 (See
the connector locations), [16] and (2) (for dis-
Outline connection).
q Vent (modes) are changed over to defroster,
foot and face by changing the three damper 3. If the man-shaped mark blinks (See the self-
angle. The damper angle is set by the mode diagnosis), check if links (3) – (5) have stopped
actuator through the link and rod. Check the halfway with operation of mode switch and
link visually. defroster switch. If the links have stopped,
a To reset the self-diagnosis system (stop blink- remove the cause (hitch, interference, foreign
ing "man-shaped mark" on the LCD), the start- matter, etc.) and repair.
ing switch must be turned OFF (While "man-
shaped mark" on the LCD is blinking, no sig- 4. Turn the power of the air conditioner OFF and
nals are output to the mode actuator since the then turn the starting switch OFF. (Resetting of
self-diagnosis system has detected a prob- problem)
lem).
5. Turn the starting switch ON and then turn the
1. Remove cover (1). power of the air conditioner ON.
q A/C U: Air conditioner unit
6. Operate the mode switch and defroster switch
(See the self-diagnosis) and check that link (3)
- (5) moves normally together.
a If the above parts do not move smoothly,
clean them and apply grease to the links.
2 Link: Grease (G2-LI)
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q DEF
q FACE/FOOT
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7. When connectors [19] and [20] are connected a Auto air conditioner
securely,
1) Remove the blower intake unit (B/I U).
2) Referring to Structure and function or
Parts book, disassemble blower intake
unit (B/I U) (only the blower side).
3) Check lever (5) between damper (D) and
damper actuator (4) to see if it has come
off and repair it if necessary.
4) Check connector [23] (damper actuator
connector) (for disconnection).
5) Assemble the blower unit and connect
connectors [20] and [23].
6) Turn starting switch ON, turn the power of
the air conditioner ON, and perform step
4. (After checking, assemble and install
the blower intake unit (B/I U).
a For electric problems, see "Trouble-
shooting for FRESH/RECIRC air
changeover".
*: To blower
*: To blower
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q If an error is detected by the self-diagnosis, q If the result is abnormal, remove the air
perform these tests. conditioner unit (See Disassembly and
q To reset the self-diagnosis system (detection of assembly, "Removal and installation of air
trouble), the starting switch must be turned conditioner unit") and replace the evapo-
OFF. rator temperature sensor (3) from evapo-
rator (2) (See the disassembly drawing in
1. Remove cover (1). Structure and function).
q A/C U: Air conditioner unit a Precautions for exchanging evaporator
temperature sensor (installed position (P)
of evaporator temperature sensor)
With the flange outlet (OUT) of the evapo-
rator on the right side, install the evapora-
tor temperature sensor so that its top will
be 100 ± 5 mm above the fin top face and
its body will be at the center (P) of the 8th
stage of the fins. (Insert and attach the
sensor holder (4) to the 10th and 11th
stages of the fins.)
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a Auto air conditioner equipped machine only. 4. Disconnect connector C48 from the air condi-
tioner control panel in line with item 10 from
q When sunlight is strong, control panel compen- "Parts and connectors layout".
sates air mix actuator and lower the blowing 5. Ensure that the female terminals of the con-
out target temperature. nector C60 (harness side) are not being
shorted. (If the terminals are shorted, the har-
a If sunlight sensor (S) is mesured with resis- ness is defective.)
tance range of tester, sunlight sensor may be 6. Confirm whether the condition between the
destroyed, so measure it with voltage range of female terminal of the connector C60 (harness
tester. side) (2) (LgR) and the terminal of connector
C48 (harness side) (15) (LgR) is 1 z or less.
1. Disconnect connector C10 inside cigar lighter (If not, the wiring harness is defective.)
(1). 7. Confirm whether the condition between the
2. Remove cover (2) and inspect the connector female terminal of connector C60 (harness
C60 for the sunlight sensor (S) (Check whether side) (1) (RB) and the terminal of connector
the connector has been partially discon- C48 (harness side) (13) (RB) is 1 z or less. (If
nected.) this is not the case, the harness is defective.)
3. Disconnect connector C60, and using a tester 8. Connect all the connectors.
set to the voltage range, measure the voltage 9. Turn the starting switch to ON position, and if
between the male side terminals on the sun- target temperature dose not change when the
light sensor (S). sunlight sensor is exposed to the sunlight at
q Approximate voltage of sunlight sensor auto air conditioner, replace the air conditioner
unit control panel.
0.45 V: Direct sunlight
0.35 V: Cloudy
0.2 V: Indoors
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Testing relays 1
q If the air conditioner compressor is normal (air 4. If either relay seems to be abnormal, perform
is cooled) and air comes out, the relays are the following procedure.
normal. Accordingly, skip these relay tests. 1) Turn the main power of the air conditioner
q Bring your ear to each relay to check its opera- OFF and disconnect the battery ground
tion by sound. wire.
2) Remove the relay mounting screws and
There are two relays. exchange the blower-off relay (BR) and
q Blower-off relay: Used to turn the fan motor ON compressor relay (CR).
and OFF 3) Connect the battery ground wire and per-
q Compressor relay: Used to turn the air condi- form steps 2 and 3 above and see if the
tioner compressor (clutch) ON and OFF conditions of the relays are reversed.
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Troubleshooting chart 1 1
a The numbers in the boxes are the item numbers in the troubleshooting table.
1. Cooling trouble
2. Heating trouble
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Troubleshooting chart 2 1
1. Blower fan motor does not revolve or its speed is different from set value.
a See "Troubleshooting for blower motor system (No air comes out or air flow is abnormal)".
3. Low/high pressure
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8. Other items
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Problem Air conditioner does not operate due to power supply system failure.
Indication of • When main power of control panel is turned ON and switch is pressed, no LCD on control panel
problem on lights up.
machine • No air comes out (Blower motor does not rotate).
• Referring to "Parts and connectors layout", check fuse No. 10 (20A) in the fuse box A and 5A fuse
in air conditioner unit (wiring harness) for breakage.
Related
• Air conditioner ground wire is grounded together with that of machine wiring harness for machine
information
electric components.
• For each connector, see "Parts and connectors layout".
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a Manual air conditioner does not have sunlight sensor, inside air temperature sensor and outside air tem-
perature sensor.
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Troubleshooting for blower motor system (No air comes out or air flow
is abnormal) 1
Problem No air comes out or air flow is abnormal due to blower motor system failure.
Indication of • When main power of control panel is turned ON, LCD on control panel lights up but air does not
problem on come out.
machine • Air flow does not match fan switch setting of control panel.
• This trouble cannot be checked with self-diagnosis function.
• Referring to "Parts and connectors layout", check 15A fuse in air conditioner unit for breakage.
• If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. In this case,
the probable causes are as follows.
1)Defective compressor relay, (stuck close) See "Testing relays".
Related
2)Evaporator temperature sensor mounting clip may have come off.
information
3)Expansion valve may not be adjusted correctly. (Remove and disassemble air conditioner unit.)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
• If air flow is also abnormal in heating mode, replace blower amplifier first.
• For each connector and relay, see "Parts and connectors layout".
• Since blower intake unit is independent (under cab), disconnect it first.
q Manual air conditioner
Causes Standard value in normal state/Remarks on troubleshooting
1) Turn starting switch OFF.
2) Disconnect connector [20] from under cab and connect T-
adapter to it.
3) Carry out troubleshooting with connector [19] disconnected and
starting switch kept OFF.
Between wiring harness (1) (R/W) and (3)
(orange) of connector [20] (on blower motor There is continuity
side)
Defective blower (fan) motor
1 or defective wiring harness in 1) Turn starting switch OFF.
blower intake unit 2) Disconnect connector [20] from under cab and insert T-adapter
(Connect connectors [19] and [20]).
3) Turn starting switch ON, turn main power of control panel ON,
set fan switch to HI-MAX, and carry out troubleshooting.
a If following voltage is not applied, go to cause 4.
Between wiring harness (1) (R/
W) and (3) (orange) of
Voltage 20 – 30 V
Possible causes connector [20] (on blower motor
and standard side)
value in normal a If check result of cause 1 is abnormal (continuity is broken or
state motor does not rotate while voltage is normal), perform follow-
ing procedure.
1) Turn starting switch OFF.
2) Remove blower intake unit.
3) Referring to Structure and function, disassemble blower intake
Defective wiring harness in unit. (Disconnect connector [24])
2
blower intake unit Orange line between connectors Resis-
Max. 1 z
[20] and [24] tance
RW line between connectors Resis-
Max. 1 z
[20] and [24] tance
Between (1) (RW) and (3) Resis-
Min. 1 Mz
(orange) of connector [20] tance
a If check result of cause 1 is abnormal (continuity is broken or
motor does not rotate while voltage is normal) and check result
3 Defective blower (fan) motor of cause 2 is normal, blower (fan) motor is defective.
a If blower (fan) motor coil is burnt and broken because of short
circuit, fuse (15A) is also broken.
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Referring to "Connection of service tool", carry out <Measurement condition for pressure>
troubleshooting by reading the high and low gauge Item Condition value
pressures of the cooling cycle.
Atmospheric temperature 20 – 50°C
a The gauge pressure varies largely with the Engine speed Low idle
weather condition and operating condition of Air conditioner switch ON
the machine. Take care. Fan switch Hl
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*1 If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are
stained with oil. Increase tightening of the joints or replace parts.
*2. k When replacing a cooling cycle part, see "Caution about refrigerant" and collect refrigerant. After replacing it, fill
up the air conditioner system with refrigerant again.
*3. Sight glass is on the receiver drier.
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a Use the service tool kit for R134a. Connect the gauge manifold, hoses and other ser-
vice tools according to the following procedure.
Service tool kit
1. Gauge manifold 1. Close the high-pressure valve (HI) and low-
2. High pressure charging hose (red) pressure valve (LO) of gauge manifold (1).
3. Low pressure charging hose (blue) 2. Connect red charging hose (2) to the (HI) side
4. Quick joint (Hi) (Large diameter) and blue charging hose (3) to the (LO) side.
5. Quick joint (Lo) (Small diameter) 3. Connect quick joints (4) and (5) to each hose.
a. The thread is rough. So be careful not to loosen. 4. Connect the quick joints to the service valves
of the high and low-pressure pipings.
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1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
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©2018 KOMATSU
All Rights Reserved
Printed in Japan 06-18 (01)
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Greasing parts
1. Bucket pin (left)
2. Bucket pin (right)
3. Lift arm pivot pin (left)
4. Lift arm pivot pin (right)
5. Bucket link pin (bucket side)
6. Bucket link pin (bell crank side)
7. Bell crank pin
8. Bucket cylinder head pin
9. Bucket cylinder bottom pin
10. Lift cylinder bottom pin (right)
11. Lift cylinder head pin (right)
12. Lift cylinder bottom pin (left)
13. Lift cylinder head pin (left)
14. Drive shaft center support
15. Steering cylinder bottom pin (left)
16. Steering cylinder bottom pin (right)
17. Center hinge pin (upper)
18. Center hinge pin (lower)
19. Steering cylinder head pin (left)
20. Steering cylinder head pin (right)
21. Rear axle pivot pin (rear side)
22. Rear axle pivot pin (rear side)
23. Rear axle pivot pin (front side)
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© 2017 KOMATSU
All Rights Reserved
Printed in Japan 07-17 (01)
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Electrical circuit diagram (1/7)
Electrical circuit diagram WA500-6 1
(1/7)
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Electrical circuit diagram (2/7)
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Electrical circuit diagram (5/7)
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Electrical circuit diagram (6/7)
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Connector arrangement diagram
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Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
1.PS DT2 2 1st ECMV solenoid AI-3 E11 DT2 2 Diode AE-5 JT2 DT2 6 Junction connector AI-6 LS2 DT2(Gr) 12 Intermediate connector (Floor – right console) U-2
1.SW DT 2 1st ECMV fill switch AI-3 E15 DT2 2 Dust indicator AD-9 JT3 DT2 6 Junction connector AN-7 LS3 DT2(Br) 12 Intermediate connector (Floor – right console) V-2
2.PS DT2 2 2nd ECMV solenoid AK-1 E16 DT2 2 Air conditioner compressor AD-1 KOM DT2A 12 Intermediate connector (KOMTRAX) Y-7 LS4 DT2(G) 12 Intermediate connector (Floor – right console) V-2
2.SW DT 2 2nd ECMV fill switch AL-2 E17 DT2 2 Diode AE-5 L01 Terminal 1 GND (Floor frame) X-4 LS8 DT2 4 Intermediate connector (3-spool valve EPC lever)
3.PS DT2 2 3rd ECMV solenoid AM-5 E18 DRC26 50 Engine controller AH-2 L02 DRC26 24 Transmission controller W-7 LT1 HD30 31 Intermediate connector (Floor – transmission) AI-6
3.SW DT 2 3rd ECMV fill switch AM-5 E19 DTP 4 Engine controller AG-1 L03 DRC26 40 Transmission controller X-7 NE FRAMATONE 3 Ne speed sensor AH-2
4.PS DT2 2 4th ECMV solenoid AL-2 E21 DT2 3 CAN terminal resistance AH-2 L04 DRC26 40 Transmission controller X-7 PAMB FRAMATONE 3 Ambient pressure sensor AH-2
4.SW DT 2 4th ECMV fill switch AM-3 E22 Terminal 1 GND (Engine unit) AD-2 L05 DRC26 24 Work equipment controller V-8 PB.PS DT2 2 Parking brake solenoid AN-6
AL1 DT2 6 Intermediate connector (Air conditioner unit) R-1 E31 Terminal 1 Heater AD-3 L06 DRC26 40 Work equipment controller W-8 PB.SW DT2 2 Parking brake indicator switch AJ-2
B01 DT2 2 Left brake oil pressure sensor N-4 E32 Terminal 1 Heater relay L-9 L07 DRC26 40 Work equipment controller W-7 PCV1 SUMITOMO 2 Supply pump AD-2
B02 DT2 2 Lift arm EPC cut-off solenoid N-4 EGR DT-T 2 EGR valve solenoid AE-5 L08 DT2(Gr) 12 Intermediate connector (VHMS wiring harness) X-5 PCV2 SUMITOMO 2 Supply pump AD-2
B03 DT2 2 Diode N-3 ENG DRC 60 Engine controller AG-1 L10 M 6 Intermediate connector (Printer wiring harness) W-8 EGR valve inlet pressure sensor (Applicable machine serial
PEVA FRAMATONE 3 AD-3
No: 55001 – 55120)
B04 DT2 2 Brake accumulator low pressure switch (Rear) L-2 ER1 DT2(B) 12 Intermediate connector (Engine) J-3,AE-5 L11 DT2 2 Pneumatic suspension seat W-7
PFUEL AMP 3 Common rail pressure sensor AG-1
B05 DT2 2 Brake accumulator low pressure switch (Front) K-3 ER2 DT2 12 Intermediate connector (Engine controller) J-4,AD-5 L14 DT2 2 Spare O-2
PIM SUMITOMO 4 Charge pressure (Boost pressure) sensor AH-4
B06 DT2 2 Rear emergency brake switch L-2 ER3 L 2 Intermediate connector (Engine controller) J-5,AD-5 L15 DT2 8 Accelerator pedal O-2
POIL SUMITOMO 3 Engine oil pressure sensor AG-1
B07 DT2 2 Front emergency brake switch K-3 F.PS DT2 2 F (Forward) ECMV solenoid AM-4 L16 DT2 2 Stop lamp switch U-1
R.PS DT2 2 R (Reverse) ECMV solenoid AM-3
B09 KES0 2 Front windshield washer N-5 F.SW DT1 2 F (forward) ECMV fill switch AM-4 L17 M 4 DC24V/DC12V converter V-8
R.SW DT 2 R (Reverse) ECMV fill switch AM-4
B10 Terminal 1 GND (Rear frame) K-5 F01 DT2 6 Intermediate connector (Right combination lamp, headlamp) A-5 L19 KES1 4 Flasher unit X-4
R01 Terminal 1 Circuit breaker SBF1 L-9
B11 KES0 2 Rear windshield washer N-6 F02 DT2 6 Intermediate connector (Left combination lamp, headlamp) A-3 L20 M 2 Caution buzzer X-6
R02 Terminal 1 Circuit breaker SBF1 L-9
B12 DT2 2 Diode K-4 F03 AMP 090 2 Horn Lo A-4 L21 KES1 6 Interval wiper timer X-5
R03 Terminal 1 Circuit breaker SBF2 N-9
B13 DT2 2 Diode K-5 F05 AMP 090 2 Horn Hi A-5 L22 S 10 Front/Rear wiper switch R-1
R04 Terminal 1 Circuit breaker SBF2 N-9
BL1 DT2(B) 12 Intermediate connector (Brake component box) N-5 F07 DT2 2 Lift arm raise EPC solenoid B-2 L25 X 1 Optional connector X-5
R05 Terminal 1 Circuit breaker SBF2 N-8
BP DT-T 2 Bypass valve AE-4 F08 DT2 2 Lift arm lower EPC solenoid C-1 L26 DT1 1 Optional connector U-8
R06 Terminal 1 Circuit breaker SBF3 N-8
C01 YAZAKI 9 AM/FM radio D-8 F09 DT2 2 Bucket tilt EPC solenoid C-1 L26 DT2(B) 8 Intermediate connector (3rd EPC)
R07 Terminal 1 Slow blow fuse SBF3
C02 M 2 Speaker (Right) F-9 F10 DT2 2 Bucket dump EPC solenoid B-1 L27 SWP 6 Spare (Wiper)
R08 Terminal 1 Slow blow fuse SBF2
C03 M 2 Speaker (Left) F-9 F11 DT2 3 Bucket level positioner proximity switch A-4 L31 Terminal 1 Emergency parking release switch X-6
R09 Terminal 1 GND (Rear frame) J-6
C04 M 2 Front working lamp (Right) C-7 F12 DT2 3 Bucket tilt sensor proximity switch A-3 L32 Terminal 1 Emergency parking release switch X-6
R10 Terminal 1 GND (Rear frame) I-8
C05 M 2 Front working lamp (Left) B-7 F13 DT2 3 Lift arm angle sensor E-1 L34 Terminal 1 Emergency parking release switch X-6
R11 Terminal 1 Disconnecting switch
C07 KES1 2 Room lamp F-9 F14 DT2 3 Lift arm bottom pressure sensor (Load meter specification) D-1 L35 Terminal 1 Emergency parking release switch X-6
R11 DT2 2 Parking brake emergency release solenoid H-2
C08 M 1 Right door switch (Room lamp) C-8 F15 DT2 3 Lift arm rod pressure sensor (Load meter specification) D-1 L36 YAZAKI 2 12V DC outlet V-8
R12 X 2 Transmission oil filter clogging sensor H-2
C09 M 1 Left door switch (Room lamp) B-7 F16 DT2 3 Loader pump pressure sensor B-1 L45 D-sub 25 Printer (If equipped)
R13 DT2 2 Coolant level sensor H-2
C10 YAZAKI 2 Cigarette lighter B-7 F20 Terminal 1 Ground (Front frame) A-3 L46 HOSHIDEN 4 Printer (If equipped)
R14 Terminal 1 Heater relay L-8
C12 M 6 Front wiper motor A-6 F21 DT2 4 3-spool valve (Attachment) EXT EPC solenoid (If equipped) L51 AMP 20 Machine monitor P-1
R15 Terminal 1 Heater relay L-9
C15 M 4 Rear wiper motor G-9 F22 DT2 2 3-spool valve (Attachment) RET EPC solenoid (If equipped) L52 AMP 18 Machine monitor P-2
R16 DT2 2 Fuel level sensor J-4
C17 SWP 6 Auto grease switch (If equipped) E-9 F24 DT2 2 E.C.C.S. solenoid A-2 L53 AMP 12 Machine monitor O-2
R17 DT2 12 Rear brake oil temperature sensor J-3
C18 DT 2 Warning lamp (If equipped) B-7 F31 DT-T 2 Multi-coupler extension solenoid (If equipped) L54 AMP 18 Machine monitor O-4
R18 DT2 2 Battery electrolyte level sensor J-6
C18A M 1 Auto grease (If equipped) A-7 F32 DT-T 2 Diode (If equipped) L55 AMP 12 Machine monitor O-5
R38 DT2 6 Auto grease controller (If equipped)
C19 SWP 6 Rear glass heater switch E-9 F33 DT-T 2 Multi-coupler retraction solenoid (If equipped) L56 AMP 12 Machine monitor P-2
R87 DT 2 Intermediate connector (Front frame GND)
C22 DT 3 Rotary lamp (If equipped) F34 DT-T 2 Diode (If equipped) L57 AMP 14 Machine monitor O-5
RES DT 2 Resistor AH-3
C25 X 4 Intermediate connector (Warning lamp, rotary lamp) C-8 FL1 DRC16 40 Intermediate connector (Floor – front frame) X-3 L58 SWP 6 Parking brake switch O-5
REV OUT1 DT2 2 Speed sensor 1 AK-8
C29 M 1 Glass heater (If equipped) D-8 FL4 DT2 4 Intermediate connector (Attachment EPC solenoid) L59 SWP 6 E.C.S.S. switch S-1
REV OUT2 DT2 2 Speed sensor 2 AI-4
C33 Terminal 1 Rear glass heater E-9 G SUMITOMO 3 Bkup speed sensor AD-1 L61 SWP 6 Light switch/Dimmer switch Q-1
RG1 DT2 6 Intermediate connector (Auto grease (If equipped)) G-2
C35 Terminal 1 Rear glass heater G-9 G01 DT2 6 Right rear combination lamp H-9 L62 SWP 6 Turn and hazard switch P-6
RS1 DT2 2 Left side working lamp (If equipped) I-3
C39 Terminal 1 Radio GND D-8 G02 DT2 6 Left rear combination lamp J-7 L63 SWP 14 Gearshift switch Q-1
RS2 DT2 2 Right side working lamp (If equipped) I-3
C40 Terminal 1 Cab GND E-9 G03 DT2 2 Right rear working lamp G-9 L64 DT2 2 Steering wheel horn switch O-6
RT1 DT2(Gr) 12 Intermediate connector (Rear frame – radiator guard) AI-4
C47 Terminal 1 Beacon GND (If equipped) C-7 G04 DT2 2 Left rear working lamp J-8 L65 SWP 6 Character display item selector switch S-1
S01 DT2 2 Lift arm neutral lock switch P-6
C47 JAE IL-AG5 22 Manual air conditioner controller D-8 G06 DT2 2 Backup buzzer H-9 L66 SWP 6 Character display mode selector switch S-1
S02 DT2 4 Lift arm and bucket EPC lever Q-8
C48 JAE IL-AG5 14 Manual air conditioner controller D-8 G09 DT2 2 Fan reverse solenoid H-9 L69 SWP 6 Load meter mode switch (If equipped) T-1
S03 DT2 4 Lift arm and bucket EPC lever Q-8
C49 DT2(B) 12 Intermediate connector (Air conditioner) G-1 GR1 DT2(Gr) 12 Intermediate connector (Radiator guard wiring harness) J-6 L70 SWP 6 Load meter display selector switch (If equipped) T-1
S04 DT2 2 Lift arm and bucket EPC lever Q-8
C50 DT2(Gr) 12 Intermediate connector (Air conditioner) G-1 HEAD DT2 3 Right headlamp A-5 L72 SWP 6 Beacon lamp switch (If equipped) O-5
S05 DT2 2 Lift arm and bucket EPC lever Q-9
C52 S 3 Multi-coupler switch E-9 HEAD DT2 3 Left headlamp F-1 L73 SWP 6 Left brake pedal switch R-1
S06 DT2 2 Lift arm and bucket EPC lever P-7
C60 AMP 2 Daylight sensor I-3 J1939 DT 3 CAN connector AG-6 L80 DRC 40 KOMTRAX Z-6
S07 DT2 4 Lift arm kick-down switch and hold switch Q-8
C65 DT 3 Alarm buzzer (If equipped) JB1 DT2(B) 6 Junction connector K-4 L101 SHINAGAWA 5 Relay No. 1 Backup lamp AB-7
S08 DT2 4 Bucket control lever (Load meter specification) Q-8
C91 M 1 Intermediate connector (Alarm buzzer) C-8 JB2 DT2 6 Junction connector L-5 L102 SHINAGAWA 6 Relay No. 2 Stop lamp AA-6
S09 DT2 4 Right gearshift switch (Steering wheel specification (If equipped)) Q-7
CAN1 DT2 3 CAN terminal resistance O-3 JB3 DT2 6 Junction connector N-3 L103 SHINAGAWA 5 Relay No. 3 Neutral safety AB-7
S10 SWP 6 Transmission cut-off ON/OFF switch R-7
CHK0 X 1 Intermediate connector (KOMTRAX) Z-6 JB4 DT2 6 Junction connector M-2 L104 SHINAGAWA 5 Relay No. 4 Lever AA-6
S11 SWP 6 RPM set ON/OFF switch S-8
CHK1 X 1 Intermediate connector (KOMTRAX) Y-7 JE1 — 6 Junction connector AE-5 L105 SHINAGAWA 5 Relay No. 5 Parking brake safety AB-8
S12 SWP 6 RPM set idle up/down selector switch S-8
CL1 SWP 8 Intermediate connector (Floor – cab wiring harness) O-3 JE2 — 6 Junction connector AE-5 L106 SHINAGAWA 5 Relay No. 6 Preheating AA-6
S13 SWP 6 Lift arm position set switch R-7
CL2 SWP 12 Intermediate connector (Floor – cab wiring harness) O-3 JF1 DT2 6 Junction connector D-1 L107 SHINAGAWA 5 Relay No. 7 Dust indicator AA-8
S14 SWP 6 Bucket position set switch R-8
CL24 X 2 Intermediate connector (Multi-coupler solenoid) (If equipped) A-6 JF2 DT2(B) 6 Junction connector E-1 L108 SHINAGAWA 6 Relay No. 8 Horn Z-6
S15 SWP 6 Hydraulic fan reverse switch S-8
CL26 X 2 Auto grease (If equipped) A-6 JF3 DT2(B) 6 Junction connector E-1 L109 SHINAGAWA 6 Relay No. 9 Front working lamp AA-8
S16 DT2 4 Auto-shift mode switch Q-7
CN1 DT 2 No. 1 injector AD-3 JF4 DT2 6 Junction connector A-4 L110 SHINAGAWA 6 Relay No. 10 Rear working lamp Y-6
S17 SWP 6 Engine power mode selector switch Q-7
CN2 DT 2 No. 2 injector AD-4 JG1 DT2(B) 12 Junction connector J-7 L111 SHINAGAWA 5 Relay No. 11 Rear glass heater AA-8
S18 SWP 6 Torque converter lockup switch Q-7
CN3 DT 2 No. 3 injector AF-5 JG2 DT2 6 Junction connector J-7 L113 SHINAGAWA 5 Relay No. 13 Hazard AA-8
S19 SWP 6 Transmission cut-off set switch R-7
CN4 DT 2 No. 4 injector AF-5 JG3 DT2 8 Junction connector J-8 L114 SHINAGAWA 6 Relay No. 14 Fan motor Y-7
S20 SWP 6 Semi auto-digging selector switch S-8
CN5 DT 2 No. 5 injector AH-5 JL1 DT2(Gr) 8 Intermediate connector (Joystick steering) AB-2 L115 SHINAGAWA 5 Relay No. 15 Headlamp Z-9
Right gearshift ON/OFF switch (Steering wheel specification
CN6 DT 2 No. 6 injector AH-5 JL2 DTM 12 Joystick lever switch AB-3 L116 SHINAGAWA 5 Relay No. 16 Coolant level Y-8 S21 SWP 6 R-8
(If equipped))
COMBI M 3 Right front combination lamp A-6 JL3 DT2 4 Intermediate connector (Joystick EPC solenoid) W-2 L117 SHINAGAWA 5 Relay No. 17 Engine control cut 1 Z-9 S25 DT2 4 3-spool valve (Attachment) EPC lever (If equipped)
COMBI M 3 Left front combination lamp F-1 JM01 — 6 Junction connector (Engine) AH-3 L118 SHINAGAWA 5 Relay No. 18 Joystick cut-off Y-8 S67 SWP 6 Front working lamp switch O-4
D01 YAZAKI 3 Diode X-3 JM02 — 6 Junction connector (Engine) AH-2 L119 SHINAGAWA 6 Relay No. 17 Engine control cut 2 Z-9 S68 SWP 6 Rear working lamp switch O-4
D01 Terminal 1 Right battery relay L-7 JM03 — 4 Junction connector (Engine) AH-2 L120 SHINAGAWA 5 KOMTRAX engine cut relay Y-8 SBP DT 4 Bypass valve AE-5
D02 YAZAKI 3 Diode X-4 JM04 — 4 Junction connector (Engine) AG-1 L141 SHINAGAWA 5 Printer power supply relay (If equipped) SEGR DT 4 EGR valve lift sensor AF-5
D02 Terminal 1 Left battery relay M-7 JM05 — 3 Junction connector (Engine) AH-3 L142 DT2 2 Diode (If equipped) T01 DT2 2 Pump EPC solenoid AN-7
D03 YAZAKI 2 Diode X-4 JM06 — 3 Junction connector (Engine) AH-3 L143 DT2 2 Diode (If equipped) T02 DT2 2 Fan pump EPC solenoid AL-9
D03 Terminal 1 Left battery relay L-8 JM07 — 4 Junction connector (Engine) AG-6 L144 DT2 2 Diode (If equipped) T03 DT2 2 Hydraulic oil temperature sensor AI-7
D04 YAZAKI 2 Diode X-4 JM08 — 6 Junction connector (Engine) AG-6 L145 DT2 2 Diode (If equipped) T04 DT2 2 Emergency steering drive switch AJ-7
D04 Terminal 1 Right battery relay L-8 JR1 — 6 Junction connector N-7 LC.PS DT2 2 Torque converter lockup ECMV solenoid AJ-2 T05 DT2 2 Torque converter oil temperature sensor AK-8
D11 Terminal 1 Disconnecting switch JR2 — 6 Junction connector M-7 LR1 DTHD4 1 Intermediate connector (Slow blow fuse) W-3 TFUEL PACKARD 2 Fuel temperature sensor AH-4
DIODE1 DT2 2 Diode AI-5 JS1 SWP 6 Joystick ON/OFF switch (Joystick steering specification) AA-4 LR2 DT 2 Intermediate connector (Multi-coupler solenoid) (If equipped) TGN Terminal 1 Transmission body GND AN-6
E01 DT2 2 Starting motor AC-5 JS2 SWP 6 Steering speed mode switch (Joystick steering specification) Z-4 LR2 L 2 Intermediate connector (Slow blow fuse) V-2 TIM PACKARD 2 Charge temperature (Boost temperature) sensor AH-4
E03 Terminal 1 Alternator terminal R AF-7 JS3 DT2 4 Joystick lever potentiometer (Joystick steering specification) Y-4 LR3 L 2 Intermediate connector (Slow blow fuse) V-2 TM.T DT2(B) 2 Transmission oil temperature sensor AI-5
E04 Terminal 1 Alternator terminal B AF-7 JS4 DT2 2 Joystick neutral lock switch (Joystick steering specification) AA-2 LR4 L 2 Intermediate connector (Rear frame GND) X-3 TWTR PACKARD 2 Coolant temperature sensor AC-7
E05 Terminal 1 Alternator terminal E AF-7 JS5 DT2 2 Joystick EPC solenoid (Joystick steering specification) Q-1 LR5 DRC12 70 Intermediate connector (Floor – rear frame) W-3
E06 Terminal 1 Alternator GND AF-6 JS6 DT2 2 Joystick EPC solenoid (Joystick steering specification) Q-1 LR6 L 2 Intermediate connector (Engine controller) W-2
E08 Terminal 1 Starting motor AC-6 JT1 DT2(B) 8 Junction connector AM-5 LS1 DT2(B) 12 Intermediate connector (Floor – right console) U-1
SEN00715-05
WA500-6 19
90 Diagrams and drawings SEN00715-05
WA500-6 21
SEN00715-05
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Printed in Japan 10-20 (01)
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