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Komatsu WA500-6 Wheel Loader Service Manual

1,736 pages · Publication SEN00236-05

$179.53
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Models
WA500-6
Serial coverage
55001 and up
Manual type
Service Manual
Pages
1,736
Publication
SEN00236-05
Condition
Brand new
Komatsu WA500-6 Wheel Loader Service Manual, publication SEN00236-05

What's inside

From the manual's own table of contents: 284 sections, 584 entries. See sample pages (PDF, 769 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification and technical data
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine and cooling system
Cooling system
Engine mount and transmission mount
Power train, Part 1
Power train
Power train system diagram
Joint
Drive shaft
Show all 284 sections
Power train piping diagram
Torque converter
Torque converter regulator valve
Transmission
Transfer
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Lubrication relief valve
Power train, Part 2
Torque converter oil cooler
Torque converter oil filter
Center support
Axle
Differential
Limited slip differential
Final drive48 topics
  • Steering system
  • Steering piping diagram
  • Steering column
  • Steering control valve
  • Steering valve
  • Stop valve
  • Joystick steering lever linkage (if equipped)
  • Steering cylinder
  • Emergency steering piping diagram (if equipped)
  • Diverter valve
  • Brake system
  • Brake piping diagram
  • Brake valve
  • Slack adjuster
  • Accumulator charge valve
  • PPC relief valve
  • Accumulator (for brake)
  • Brake
  • Parking brake control
  • Parking brake
  • Parking brake solenoid valve
  • Emergency parking brake release valve
  • Undercarriage and frame
  • Axle mount
  • Center hinge pin
  • Hydraulic system, Part 1
  • Hydraulic piping diagram
  • Work equipment control lever linkage
  • Hydraulic tank
  • Cooling fan motor
  • Cooling fan pump
  • Steering pump
  • Work equipment hydraulic pump
  • Hydraulic system, Part 2
  • Control valve
  • CLSS
  • Each function and operation of each valve
  • Accumulator (for PPC circuit)
  • Work equipment electric lever
  • Work equipment
  • Work equipment linkage
  • Bucket
  • Bucket positioner and boom kick-out
  • Work equipment lubrication
  • Cab and its attachments
  • ROPS cab
  • Air conditioner
  • Electrical system, Part 1
Machine monitor system
Machine monitor
Electrical system, Part 2
Work equipment control system
Transmission controller system
Electrical system, Part 3
Electric transmission control
Engine starting circuit
Engine stopping circuit
Preheating circuit
Parking brake circuit
Backup and stop lamp circuits
Small lamp and head lamp circuits
Working lamp circuit
Horn circuit
Wiper and window washer circuits
Sensor
KOMTRAX terminal system (if equipped)
Standard service value table
Standard service value table for engine
Standard service value table for chassis
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring exhaust gas color
Measuring exhaust temperature
Adjusting valve clearance
Testing compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Measuring intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Testing fuel pressure
Testing return rate and leakage
Bleeding air from fuel circuit
Testing leakage in fuel system
Handling reduced cylinder mode operation
Handling no injection cranking operation
Handling controller voltage circuit
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting transmission speed sensor
Measuring directional lever (Steering wheel specification)
Testing and adjusting power train oil pressure
Flushing procedure for torque converter and transmission hydraulic circuit
Method of moving machine when transmission valve is broken36 topics
  • Testing and adjusting, Part 2
  • Testing and adjusting steering stop valve
  • Testing and adjusting steering wheel
  • Testing steering oil pressure
  • Bleeding air from steering cylinder circuit
  • Testing hydraulic drive fan
  • Bleeding air from hydraulic drive fan circuit
  • Measuring brake pedal
  • Measuring brake performance
  • Testing and adjusting accumulator charge pressure
  • Testing wheel brake oil pressure
  • Measuring wear of wheel brake disc
  • Bleeding air from brake circuit
  • Releasing residual pressure in brake accumulator circuit
  • Testing parking brake performance
  • Measuring parking brake oil pressure
  • Testing wear of parking brake disc
  • Method of releasing parking brake manually
  • Measuring and adjusting work equipment control lever
  • Testing and adjusting work equipment PPC oil pressure
  • Measuring work equipment oil pressure
  • Bleeding air from work equipment circuit
  • Releasing residual pressure in work equipment circuit
  • Method of moving machine when removing operator cab (when splittable cab is used)
  • Testing and adjusting bucket positioner
  • Testing and adjusting lift arm position detecting lever
  • Checking proximity switch operation indication lamp
  • Procedure for testing diodes
  • Preparations for work on troubleshooting of electrical system
  • Testing and adjusting, Part 3
  • Starting KOMTRAX terminal operations (if equipped)
  • Indicator lamps of KOMTRAX terminal (if equipped)
    • and additional installation for each sensor and controller
  • Special functions of machine monitor (EMMS)
  • Testing and adjusting, Part 4
  • Pm click inspection table
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Testing before troubleshooting
Classification and procedures of troubleshooting
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Failure codes list
Before carrying out troubleshooting for electrical system
Information contained in troubleshooting table
Failure code [1500L0] (TORQFLOW transmission : Double meshing)
Failure code [15B0NX] (Transmission filter: Clogged)
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)
Failure code [2F00MA] (Parking brake: Malfunction)
Failure code [2G42ZG] (Front accumulator: Low oil pressure)
Troubleshooting by failure code (Display of code), Part 2
Failure code [2G43ZG] (Rear accumulator: Low oil pressure)
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)
Failure code [AA1ANX] (Air cleaner: Clogging)
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)
Failure code [AB00MA] (Alternator: Malfunction)
Failure code [B@BAZG] (Low engine oil pressure)
Failure code [B@BAZK] (Engine oil: Low level)
Failure code [B@BCNS] (Coolant: Overheating)
Failure code [B@BCZK] (Coolant: Low level)
Failure code [B@C7NS] (Brake oil: Overheating)
Failure code [b@CENS] (Torque converter oil: Overheating)
Failure code [B@GAZK] (Battery electrolyte: Low level)
Failure code [B@HANS] (Hydraulic oil: Overheating)
Failure code [CA111] (Abnormality in engine controller)
Failure code [CA115] (Engine Ne or Bkup speed sensor error)
Failure code [CA122] (Charge pressure sensor high error)
Failure code [CA123] (Charge pressure sensor low error)
Failure code [CA131] (Throttle sensor high error)
Failure code [CA132] (Throttle sensor low error)
Failure code [CA135] (Engine oil pressure sensor high error)
Failure code [CA141] (Engine oil pressure sensor low error)
Failure code [CA144] (Coolant temperature sensor high error)
Failure code [CA145] (Coolant temperature sensor low error)
Failure code [CA153] (Charge temperature sensor high error)55 topics
  • Failure code [CA154] (Charge temperature sensor low error)
  • Failure code [CA187] (Sensor power supply 2 low error)
  • Failure code [CA221] (Atmospheric pressure sensor high error)
  • Failure code [CA222] (Atmospheric pressure sensor low error)
  • Failure code [CA227] (Sensor power supply 2 high error)
  • Troubleshooting by failure code (Display of code), Part 3
  • Failure code [CA234] (Engine overspeed)
  • Failure code [CA238] (Ne speed sensor power supply error)
  • Failure code [CA263] (Fuel temperature sensor high error)
  • Failure code [CA265] (Fuel temperature sensor low error)
  • Failure code [CA271] (PCV1 Short circuit)
  • Failure code [CA272] (PCV1 Disconnection)
  • Failure code [CA273] (PCV2 Short circuit)
  • Failure code [CA274] (PCV2 Disconnection)
  • Failure code [CA322] (Injector #1 (L/B #1) open/short error)
  • Failure code [CA323] (Injector #5 (L/B #5) open/short error)
  • Failure code [CA324] (Injector #3 (L/B #3) open/short error)
  • Failure code [CA325] (Injector #6 (L/B #6) open/short error)
  • Failure code [CA331] (Injector #2 (L/B #2) open/short error)
  • Failure code [CA332] (Injector #4 (L/B #4) open/short error)
  • Failure code [CA342] (Calibration code inconsistency)
  • Failure code [CA351] (Injector drive circuit error)
  • Failure code [CA352] (Sensor power supply 1 low error)
  • Failure code [CA386] (Sensor power supply 1 high error)
  • Failure code [CA431] (Idle validation switch error)
  • Failure code [CA432] (Idle validation action error)
  • Failure code [CA441] (Battery voltage low error)
  • Failure code [CA442] (Battery voltage high error)
  • Failure code [CA449] Common rail pressure high error 2
  • Failure code [CA451] (Common rail pressure sensor high error)
  • Failure code [CA452] (Common rail pressure sensor low error)
  • Failure code [CA553] (Common rail pressure high error 1)
  • Failure code [CA554] (Common rail pressure sensor in-range error)
  • Failure code [CA559] (Supply pump pressure very low error)
  • Failure code [CA689] (Engine Ne speed sensor error)
  • Failure code [CA731] (Engine Bkup speed sensor phase error)
  • Failure code [CA757] (All continuous data lost error)
  • Failure code [CA778] (Engine Bkup speed sensor error)
  • Failure code [CA1228] (EGR valve servo error 1)
  • Failure code [CA1625] (EGR valve servo error 2)
  • Failure code [CA1626] (Bypass valve solenoid current high error)
  • Failure code [CA1627] (Bypass valve solenoid current low error)
  • Failure code [CA1628] (Bypass valve servo error 1)
  • Failure code [CA1629] (Bypass valve servo error 2)
  • Failure code [CA1631] (Bypass valve lift sensor high error)
  • Failure code [CA1632] (Bypass valve lift sensor low error)
  • Failure code [CA1633] (KOMNET datalink timeout error)
  • Troubleshooting by failure code (Display of code), Part 4
  • Failure code [CA1642] (EGR inlet pressure sensor low error)
  • Failure code [CA1653] (EGR inlet pressure sensor high error)
  • Failure code [CA2185] (Throttle sensor supply voltage high error)
  • Failure code [CA2186] (Throttle sensor power supply low error)
  • Failure code [CA2249] (Supply pump pressure very low error 2)
  • Failure code [CA2271] (EGR valve lift sensor high error)
  • Failure code [CA2272] (EGR valve lift sensor low error)
Failure code [CA2351] (EGR valve solenoid operation short circuit)
Failure code [CA2352] (EGR valve solenoid operation disconnect)
Failure code [CA2555] (Intake heater relay disconnection error)
Failure code [CA2556] (Intake heater relay short circuit error)
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)
Failure code [D192KA] (ECSS solenoid: Disconnection)
Failure code [D192KB] (ECSS solenoid: Short circuit)
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)1 topic
  • Short circuit with power supply line)
Failure code [D5ZHKA] (Terminal C signal: Disconnection)
Failure code [D5ZHKB] (Terminal C signal: Short circuit)
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)1 topic
  • Signal does not match engine running or stopped state)
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)
Failure code [DAF3KK] (Machine monitor: Low source voltage (input))
Failure code [DAF5KP] (Machine monitor: Low output voltage)1 topic
  • Defective communication (Abnormality in target component system))
Failure code [DAQ0KK] (Transmission controller: Low source voltage)
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)2 topics
  • Low source voltage (input))
  • Disagreement of model selection signals)
Troubleshooting by failure code (Display of code), Part 5
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)1 topic
  • Defective communication (Abnormality in target component system)
Failure code [DB90KK] Work equipment controller: Low source voltage (input)
Failure code [DB90KT] (Work equipment controller: Abnormality in controller)2 topics
  • Low source voltage (input)
  • Out of input signal range)
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)1 topic
  • Defective operation)
Failure code [DD15LD] ( t switch (Panel switch 1): Switch is kept pressed for long time)
Failure code [DD16LD] ( U switch (Panel switch 2): Switch is kept pressed for long time)
Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)
Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)42 topics
  • Switch is kept pressed for long time)
  • Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time)
    • Switch is kept pressed for long time)
  • Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree)
  • Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit)
  • Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit)
  • Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)
  • Troubleshooting by failure code (Display of code), Part 6
    • Switch is kept pressed for long time)
  • Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)
  • Failure code [DDK3KA] (Right FNR switch: Disconnection)
  • Failure code [DDK3KB] (Right FNR switch: Short circuit)
  • Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)
  • Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit)
  • Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)
  • Failure code [DDK6KA] (FNR lever switch: Disconnection)
  • Failure code [DDK6KB] (FNR lever switch: Short circuit)
  • Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
    • Switch is kept pressed for long time)
  • Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
  • Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
  • Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)
  • Failure code [DF10KA] (Transmission shift lever switch: Disconnection)
  • Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
  • Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection)
  • Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)
  • Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)
  • Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)
  • Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)
  • Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection)
  • Troubleshooting by failure code (Display of code), Part 7
  • Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit)
  • Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range)
    • Signal disagrees with operating and stopped states of engine)
  • Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)
    • Short circuit with power supply line)
  • Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)
  • Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)
    • Short circuit with power supply line)
  • Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)
    • Short circuit with power supply line)
  • Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)2 topics
  • Disconnection)
  • Analog signals disagree)
Troubleshooting by failure code (Display of code), Part 8
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)
Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree)
Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit)
Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range)
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)
Failure code [DV00KB] (Alarm buzzer: Short circuit)
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)
Troubleshooting by failure code (Display of code), Part 9
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)49 topics
  • Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)
    • Short circuit with power supply line)
  • Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)
  • Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)
    • Short circuit with power supply line)
  • Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)
  • Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)
  • Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)
  • Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)
    • Shorted with the power source)
  • Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)
  • Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)
  • Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)
  • Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)
  • Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)
  • Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)
  • Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)
  • Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
  • Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
  • Troubleshooting by failure code (Display of code), Part 10
  • Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
  • Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
  • Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
  • Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
  • Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
  • Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
  • Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
  • Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
  • Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
  • Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)
  • Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection)
  • Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)
    • Short circuit with power supply line)
  • Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)
  • Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)
    • power supply line)
  • Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)
  • Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)
    • power supply line)
  • Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)
  • Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)
  • power supply line)
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information in troubleshooting table
Engine does not start
Wiper does not operate
Windshield washer does not operate
Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
Working lamp does not light up or go off
Turn signal lamp and hazard lamp do not light up or go off
Brake lamp does not light or it keeps lighting up
Backup lamp does not light or it keeps lighting up
Backup buzzer does not sound or it keeps sounding
Horn does not sound or it keeps sounding
Alarm buzzer does not sound or it keeps sounding
Air conditioner does not operate or stop
KOMTRAX system does not work properly
Troubleshooting of hydraulic and mechanical system (H-mode)
Method of using troubleshooting chart
Table of failure modes and causes
Machine does not start1 topic
  • [Machine with lockup clutch (if equipped)]
Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)]1 topic
  • 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
Steering does not turn [Machine with joystick steering (if equipped)]
Steering response is low
Turning response of steering is poor [machine with joystick steering (if equipped)]
Steering is heavy
When machine turns, it shakes or makes large shocks1 topic
  • [machine with joystick steering (if equipped)]
Wheel brake does not work or does not work well
Wheel brake is not released or it drags
Parking brake does not work or does not work well
Parking brake is not released or it drags (including emergency release system)
Lift arm does not rise
Lift arm speed is low or rising force of lift arm is insufficient
When rising, lift arm comes to move slowly at specific height
Lift arm cylinder cannot hold down bucket (Bucket floats)
Hydraulic drifts of lift arm occur often
Lift arm wobbles during operation
Bucket does not tilt back
Bucket speed is low or tilting back force is insufficient
Bucket comes to operate slowly in the midst of tilting-back
Bucket cylinder cannot hold down the bucket
Hydraulic drifts of bucket occur often
Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)
During operation of machine, engine speed lowers remarkably or engine stalls44 topics
  • Large shocks are made when work equipment starts and stops
  • When work equipment circuit is relieved singly, other work equipment moves
  • ECSS does not operate, and pitching and bouncing occur
  • Troubleshooting of engine (S-mode)
  • Engine does not start easily
  • Engine does not start
  • Engine does not pick up smoothly
  • Engine stops during operation
  • Engine does not rotate smoothly (Engine hunts.)
  • Engine lacks output (or lacks power)
  • Exhaust smoke is black (Incomplete combustion)
  • Oil is consumed much (or exhaust gas color is blue)
  • Engine oil becomes contaminated quickly
  • Fuel consumption is excessive
  • Coolant contains oil (blows back or reduces)
  • Oil pressure drops
  • Oil level rises (Water, fuel in oil)
  • Coolant temperature rises too high (Overheating)
  • Abnormal noise is made
  • Vibration is excessive
  • General information on disassembly and assembly
  • How to read this manual
  • Coating materials list
  • Special tool list
  • Sketches of special tools
  • Removal and installation of engine assembly
  • Removal and installation of radiator assembly
  • Removal and installation of air aftercooler
  • Removal and installation of cooling fan and fan motor assembly
  • Removal and installation of radiator guard and cooling fan motor assembly
  • Removal and installation of fuel tank assembly
  • Removal and installation of hood
  • Engine (SAA6D140E-5)
  • Removal and installation of fuel supply pump assembly
  • Removal and installation of cylinder head assembly
  • Removal and installation of fuel injector assembly
  • Removal and installation of engine front seal
  • Removal and installation of engine rear seal
  • Power train, Part 1
  • Removal and installation of torque converter and transmission assembly
  • Disconnection and connection of power train unit
  • Disassembly and assembly of input transfer assembly
  • Disassembly and assembly of torque converter assembly (Lockup specification)
  • Disassembly and assembly of torque converter assembly (Lockup-less specification)
Disassembly and assembly of transmission assembly
Disassembly and assembly of transfer and parking brake assembly
Removal and installation of front axle assembly
Removal and installation of rear axle assembly
Power train, Part 3
Removal and installation of front differential assembly
Disassembly and assembly of differential assembly (LSD specification)
Disassembly and assembly of differential assembly (LSD-less specification)
Disassembly and assembly of final drive assembly (Front and rear)
Removal and installation of brake assembly (Front and rear)
Disassembly and assembly of brake assembly (Front and rear)
Disassembly and assembly of slack adjuster assembly
Disassembly and assembly of brake accumulator charge valve assembly
Removal and installation of center hinge pin
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of cooling pump assembly
Removal and installation of fan pump assembly
Removal and installation of work equipment pump assembly
Removal and installation of steering, torque converter charge and EPC pump assembly
Removal and installation of work equipment valve assembly
Disassembly and assembly of work equipment control valve assembly
Disassembly and assembly of steering cylinder assembly
Disassembly and assembly of lift arm and/bucket cylinder assembly
Removal and installation of steering valve assembly
Removal and installation of work equipment assembly
Removal and installation of large counterweight assembly
Removal and installation of small counterweight assembly
Removal and installation of operator's cab glass (Stuck glass)
Disassembly and assembly of operator’s seat assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of transmission controller assembly
Removal and installation of work equipment controller assembly
Removal and installation of air conditioner unit assembly12 topics
  • Power train hydraulic circuit diagram
  • Brake hydraulic circuit diagram
  • Work equipment hydraulic circuit diagram
  • Air conditioner electrical circuit diagram
  • Electrical circuit diagram (1/7)
  • Electrical circuit diagram (2/7)
  • Electrical circuit diagram (3/7)
  • Electrical circuit diagram (4/7)
  • Electrical circuit diagram (5/7)
  • Electrical circuit diagram (6/7)
  • Electrical circuit diagram (7/7)
  • Connector arrangement diagram

Inside this manual

Real pages from this service manual (1,736 pages). Open the sample pages (PDF, 768 KB)

Sample pages from the Komatsu WA500-6 Wheel Loader Service Manual: Troubleshooting, Specifications, Diagram, Foldout diagram
  • Troubleshooting, page 878: Troubleshooting by failure code (Display of code), Part 3
  • Specifications, page 1,346: E-10 Horn does not sound or it keeps sounding
  • Diagram, page 1,632: 50 Disassembly and assembly
  • Foldout diagram, page 1,729: Electrical circuit diagram (2/7)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the WA500-6 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN00236-05$179.53
Other manuals for the WA500-6

Operator's manuals

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This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,736 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Komatsu WA200PZ-6, WA430-6, WA250PZ-6, WA470-6, WA320PZ-6, WA480-6, WA380-6, WService Manual · SEN05663-00 · $69.59Komatsu WA500-6Service Manual · CEBM022903 · $209.71Komatsu WA500-6Service Manual · SEN00236-19 · $189.85Komatsu WA500-6Service Manual · VEBM430101 · $179.73Komatsu WA500-6 with SAA6D140E-5 EngineService Manual · CEBM018104 · $209.75

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).