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Komatsu WA500-7 Wheel Loader Service Manual

2,523 pages · Publication SEN05693-04

$259.61
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Models
WA500-7
Serial coverage
10001 and up
Manual type
Service Manual
Pages
2,523
Publication
SEN05693-04
Condition
Brand new
Komatsu WA500-7 Wheel Loader Service Manual, publication SEN05693-04

What's inside

From the manual's own table of contents: 381 sections, 700 entries. See sample pages (PDF, 836 KB)

Index and foreword
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table
Specification
Specifications
Specification drawing
Specification
Weight table
Table of fuel, coolant, and lubricants
Structure and function
Engine and cooling system
Show all 381 sections
Engine related parts
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Engine mount and transmission mount
Joint
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train system
Drive shaft
Power train piping drawing
Transmission control
Torque converter
Torque converter regulator valve
Transmission
Transfer
Transmission control valve
Forward and reverse clutch ECMV and gear speed clutch ECMV
Lockup clutch ECMV
Main relief valve, torque converter relief valve, and main flow selector valve
Torque converter oil cooler
Center support
Lubricating oil relief valve
Axle2 topics
  • Differential
  • Final drive
Steering system10 topics
  • Layout of steering parts
  • Steering column
  • Joystick steering lever linkage
  • Steering pump
  • Steering control valve
  • Orbitrol valve
  • Stop valve
  • Emergency steering piping diagram
  • Diverter valve
  • Emergency steering pump
Brake system10 topics
  • Layout of brake parts
  • Charge valve
  • Brake valve
  • Slack adjuster
  • Accumulator (for brake)
  • Brake
  • Parking brake control
  • Parking brake
  • Parking brake solenoid valve
  • Parking brake emergency release valve
Undercarriage and frame3 topics
  • Axle mount
  • Center hinge pin
  • Tire
Hydraulic system12 topics
  • Hydraulic component layout
  • Work equipment control
  • Hydraulic tank
  • Double type gear pump
  • Work equipment pump
  • Control valve
  • CLSS
  • Hydraulic circuit diagram and names of valves
  • Accumulator charge valve
  • Work equipment lock solenoid valve
  • Accumulator (for PPC circuit)
  • Accumulator (for ECSS)
Work equipment4 topics
  • Work equipment linkage
  • Bucket
  • Bucket positioner and boom positioner
  • Lubrication of work equipment
Cab and its attachments1 topic
  • ROPS cab
Electrical system10 topics
  • Engine control system
  • Preheating system
  • Power mode selector circuit
  • Engine output limit function
  • Automatic warm-up function
  • Parking brake control system
  • System operating lamp function
  • Battery disconnect switch function
  • Backup lamp and brake lamp
  • Clearance lamp and headlamp
Working lamp
Horn circuit
Wiper and window washer circuit
Transmission controller system
Work equipment control system
Machine monitor system
Rear view monitor system
KOMTRAX system
System component parts
Sensor
Standard value tables
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system
Testing and adjusting
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Testing engine speed
Testing boost pressure
Testing exhaust gas temperature
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing EGR valve and KVGT driving oil pressure
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Testing of KDPF and muffler stack for looseness and damage
Testing of installed condition of cylinder heads and manifolds
Testing engine piping for damage and looseness
Replacing and adjusting belt for alternator and air conditioner compressor
Procedures for cleaning fuel doser
Writing compensation values at replacement of injector and engine controller
Adjusting transmission output speed sensor
Adjusting transmission input speed sensor
Flushing procedure for torque converter and transmission hydraulic circuit
Retrieval of disabled machine due to transmission valve failure
Testing oil leakage from axle final drive
Testing drive shaft for looseness, backlash, and damage
Testing and adjusting power train oil pressure
Testing directional lever
Testing steering wheel
Testing work equipment control lever
Testing and adjusting steering circuit oil pressure
Bleeding air from steering cylinder circuit
Testing and adjusting steering stopper valve28 topics
  • Testing brake pedal
  • Testing and adjusting brake pedal linkage
  • Adjustment procedure of transmission cut-off proximity switch of left brake pedal
  • Testing braking performance
  • Testing and adjusting of brake accumulator charge pressure
  • Testing wheel brake oil pressure
  • Testing lowering of wheel brake pressure
  • Testing wear of wheel brake disc
  • Bleeding air from wheel brake circuit
  • Releasing remaining pressure in brake accumulator circuit
  • Testing parking brake performance
  • Testing parking brake oil pressure
  • Testing wear of parking brake disc
  • Method of releasing parking brake manually
  • Testing fan speed
  • Testing fan pump circuit oil pressure
  • Bleeding air from hydraulic fan circuit
  • Testing work equipment EPC oil pressure
  • Testing and adjusting work equipment oil pressure
  • Bleeding air from work equipment circuit
  • Releasing remaining pressure from work equipment circuit
  • Testing and adjusting bucket position detection lever
  • Testing and adjusting boom position detection lever
  • Special functions of machine monitor
  • Adjusting rearview camera angle
  • Handling voltage circuit of engine controller
  • Handling battery disconnect switch
  • Testing diodes
Pm clinic2 topics
  • Pm Clinic service
  • Check sheet
Troubleshooting
Related information on troubleshooting14 topics
  • Troubleshooting points
  • Sequence of events in troubleshooting
  • Check before troubleshooting
  • Inspection procedure before troubleshooting
  • Preparation work for troubleshooting of electrical system
  • Classification and procedures for troubleshooting
  • Symptom and troubleshooting numbers
  • Information in troubleshooting table
  • Connector list and layout
  • Connector contact identification
  • T-branch box and T-branch adapter table
  • Fuse location table
  • Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
  • Precautions when performing troubleshooting of machine monitor
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [1500L0] Double Engagement of T/M Clutches
Failure code [15B0NX] Transmission Oil Filter Clogging
Failure code [15SAL1] Release Trouble of ECMV (Forward)
Failure code [15SALH] Malfunction of ECMV (Forward)
Failure code [15SBL1] Release Trouble of ECMV (Reverse)
Failure code [15SBLH] Malfunction of ECMV (Reverse)
Failure code [15SEL1] Release Trouble of ECMV (1st clutch)
Failure code [15SELH] Malfunction of ECMV (1st)
Failure code [15SFL1] Release Trouble of ECMV (2nd)
Failure code [15SFLH] Malfunction of ECMV (2nd)
Failure code [15SGL1] Release Trouble of ECMV (3rd)
Failure code [15SGLH] Malfunction of ECMV (3rd)
Failure code [15SHL1] Release Trouble of ECMV (4th)
Failure code [15SHLH] Malfunction of ECMV (4th)
Failure code [2F00MA] Failure of Parking Brake Circuit
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [989A00] Engine Overrun Prevention Activated
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [A1U0N3] HC Desorb Request 1
Failure code [A1U0N4] HC Desorb Request 2
Failure code [AA10NX] Air Cleaner Clogging
Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@CENS] T/C Oil Temp. Overheat
Failure code [B@HANS] HYD Oil Temp. Overheat
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sensor 2 Supply Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sensor 2 Supply Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sensor Supply Volt Error59 topics
  • Failure code [CA239] Ne Speed Sens Supply Volt High Error
  • Failure code [CA271] IMV/PCV1 Short Error
  • Failure code [CA272] IMV/PCV1 Open Error
  • Failure code [CA273] PCV2 Short Error
  • Failure code [CA274] PCV2 Open Error
  • Failure code [CA322] Inj #1(L#1) Open/Short Error
  • Failure code [CA323] Inj #5(L#5) Open/Short Error
  • Failure code [CA324] Inj #3(L#3) Open/Short Error
  • Failure code [CA325] Inj #6(L#6) Open/Short Error
  • Failure code [CA331] Inj #2(L#2) Open/Short Error
  • Failure code [CA332] Inj #4(L#4) Open/Short Error
  • Failure code [CA343] ECM Critical Internal Failure
  • Failure code [CA351] Injectors Drive Circuit Error
  • Failure code [CA352] Sensor 1 Supply Volt Low Error
  • Failure code [CA356] Mass Air Flow Sensor High Error
  • Failure code [CA357] Mass Air Flow Sensor Low Error
  • Failure code [CA386] Sensor 1 Supply Volt High Error
  • Failure code [CA431] Idle Validation Sw Error
  • Failure code [CA432] Idle Validation Process Error
  • Failure code [CA441] Battery Voltage Low Error
  • Failure code [CA442] Battery Voltage High Error
  • Failure code [CA449] Rail Press Very High Error
  • Failure code [CA451] Rail Press Sensor High Error
  • Failure code [CA452] Rail Press Sensor Low Error
  • Failure code [CA515] Rail Press Sens Sup Volt High Error
  • Failure code [CA516] Rail Press Sens Sup Volt Low Error
  • Failure code [CA553] Rail Press High Error
  • Failure code [CA555] Crankcase Press High Error 2
  • Failure code [CA556] Crankcase Press High Error 3
  • Failure code [CA559] Rail Press Low Error
  • Failure code [CA595] Turbo Speed High Error 2
  • Failure code [CA687] Turbo Speed Low Error
  • Failure code [CA689] Eng Ne Speed Sensor Error
  • Failure code [CA691] Intake Air Temp Sens High Error
  • Failure code [CA692] Intake Air Temp Sens Low Error
  • Failure code [CA697] ECM Internal Temp Sensor High Error
  • Failure code [CA698] ECM Int Temp Sensor Low Error
  • Failure code [CA731] Eng Bkup Speed Sens Phase Error
  • Failure code [CA778] Eng Bkup Speed Sensor Error
  • Failure code [CA1117] Persistent Data Lost Error
  • Failure code [CA1664] KDOC Malfunction
  • Failure code [CA1691] Regeneration Ineffective
  • Failure code [CA1695] Sensor 5 Supply Volt High Error
  • Failure code [CA1696] Sensor 5 Supply Volt Low Error
  • Failure code [CA1843] Crankcase Press Sens High Error
  • Failure code [CA1844] Crankcase Press Sens Low Error
  • Failure code [CA1879] KDPF Delta P Sensor High Error
  • Failure code [CA1881] KDPF Delta P Sensor Low Error
  • Failure code [CA1883] KDPF Delta P Sens In Range Error
  • Failure code [CA1921] KDPF Soot Load High Error 1
  • Failure code [CA1922] KDPF Soot Load High Error 2
  • Failure code [CA1923] Dosing Fuel Valve 1 High Error
  • Failure code [CA1924] Dosing Fuel Valve 1 Low Error
  • Failure code [CA1925] Dosing Fuel Valve 1 In Range Error
  • Failure code [CA1927] Dosing Fuel Press Sens High Error
  • Failure code [CA1928] Dosing Fuel Press Sens Low Error
  • Failure code [CA1942] Crankcase Press Sens In Range Error
  • Failure code [CA1963] Dosing Fuel Valve 1 Servo Error
  • Failure code [CA1977] Fuel Doser Open/Short Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2265] Fuel Feed Pump Open Error
Failure code [CA2266] Fuel Feed Pump Short Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2732] Dosing Fuel Valve 2 High Error
Failure code [CA2733] Dosing Fuel Valve 2 Low Error
Failure code [CA2741] Dosing Fuel Valve Swap Error
Failure code [CA2765] Inj Trim Data Error
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error
Failure code [CA2881] Dosing Fuel Pressure Low Error 1
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3167] Fuel Doser Degradation
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error - Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [D160KA] Disconnection of Backup Lamp Relay Output
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output
Failure code [D160KY] Hot Short of Backup Lamp Relay Output
Failure code [D191KA] Disconnection of Neutral Output Relay
Failure code [D191KB] Ground Fault of Neutral Output Relay
Failure code [D191KY] Hot Short of Neutral Output Relay
Failure code [D192KA] Disconnection of ECSS Solenoid
Failure code [D192KB] Ground Fault of ECSS Solenoid
Failure code [D192KY] Hot Short of ECSS Solenoid
Failure code [D193KA] Disconnection of J/S Solenoid Cut Relay
Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay59 topics
  • Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay
  • Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay
  • Failure code [D19JKZ] Personal Code Relay Abnormality
  • Failure code [D1E6KA] Disconnection of Parking Brake Relay
  • Failure code [D1E6KB] Ground Fault of Parking Brake Relay
  • Failure code [D1E6KY] Hot Short of Parking Brake Relay
  • Failure code [D5ZHKA] Failure of Key SW C Signal
  • Failure code [D5ZHKB] Key SW C Signal Short Circuit
  • Failure code [D5ZHKZ] Failure of Key SW C Signal
  • Failure code [D5ZHL6] Disconnection of Key SW C
  • Failure code [D811MC] KOMTRAX Error
  • Failure code [D862KA] GPS Antenna Open Circuit
  • Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
  • Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
  • Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
  • Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
  • Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
  • Failure code [DAF0MB] Monitor ROM Abnormality
  • Failure code [DAF0MC] Monitor Error
  • Failure code [DAF3KK] Controller Power Source Low (MON)
  • Failure code [DAF8KB] Camera Power Supply Short Circuit
  • Failure code [DAFDKB] Monitor 12V Power Output Short Circuit
  • Failure code [DAFGMC] GPS Module Error
  • Failure code [DAFLKA] Operating Lamp Open Circuit (MON)
  • Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
  • Failure code [DAFQKR] CAN2 Discon (Monitor)
  • Failure code [DAQ0KK] Controller Power Source Low (T/M)
  • Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
  • Failure code [DAQ0MC] T/M Con Error
  • Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M)
  • Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
  • Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay
  • Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
  • Failure code [DAQLKA] Operating Lamp Open Circuit (T/M)
  • Failure code [DAQLKB] Operating Lamp Short Circuit (T/M)
  • Failure code [DAQQKR] CAN2 Discon (Transmission Con)
  • Failure code [DAQRKR] CAN1 Discon (Transmission Con)
  • Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
  • Failure code [DAZ9KQ] A/C Model Selection Abnormality
  • Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
  • Failure code [DB2QKR] CAN2 Discon (Engine Con)
  • Failure code [DB2RKR] CAN1 Discon (Engine Con)
  • Failure code [DB90KK] Drop in BBC Controller Main Power Source
  • Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC)
  • Failure code [DB90MC] BBC Error
  • Failure code [DB91KA] Disconnection of Key SW ACC (BBC)
  • Failure code [DB92KK] Solenoid Power Source Low (BBC)
  • Failure code [DB95KX] Failure of 5 V Power Source 1
  • Failure code [DB96KX] Failure of 5 V Power Source 2
  • Failure code [DB99KQ] Inconsistency of Model Selection (BBC)
  • Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)
  • Failure code [DB9LKB] Operating Lamp Short Circuit (BBC)
  • Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con)
  • Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con)
  • Failure code [DB9RMA] Inconsistency of Option Selection (BBC)
  • Failure code [DBE5KX] Failure of 5V Power Source
  • Failure code [DBE6KX] Failure of 24 V Power Source
  • Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW
  • Failure code [DDA8KY] Hot Short of Throttle Lock Set SW
Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
Failure code [DDB6L4] Neutral Signal Malfunction
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch
Failure code [DDE5KA] Failure of Emergency Steering Signal
Failure code [DDK3KA] FNR SW Input Signal Disconnection
Failure code [DDK3KB] FNR SW Input Signal Short Circuit
Failure code [DDK4KA] J/S FNR Input Signal Disconnection
Failure code [DDK4KB] J/S FNR Input Signal Short Circuit
Failure code [DDK5L4] Failure of J/S Shift Up/Down SW
Failure code [DDK6KA] FNR Lever Input Signal Disconnection
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW
Failure code [DDT0L4] Failure of Shift Mode Select SW
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal
Failure code [DDW9LD] Ground Fault of Kickdown Switch
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW
Failure code [DF10KA] Disconnection of Shift Lever Input
Failure code [DF10KB] Ground Fault of Shift Lever Input
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor
Failure code [DH21KA] Failure of Loader Pump Press. Sensor
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor
Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit
Failure code [DHT8ZG] Steering Oil Pressure Low
Failure code [DJF1KA] Disconnection of Fuel Level Sensor
Failure code [DK55KA] Failure of FNR Lever Potentio
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit
Failure code [DK55L5] Failure of FNR Lever Potentio
Failure code [DK59KA] Failure of Boom Lever Potentio (Main)
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main)
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub)
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub)
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main)
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main)
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub)
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub)
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main)
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main)
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub)
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)59 topics
  • Failure code [DK5FKA] Failure of J/S Lever Potentio (Main)
  • Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main)
  • Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree
  • Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub)
  • Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub)
  • Failure code [DKA0KA] Failure of Boom Angle Sensor
  • Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit
  • Failure code [DKA0L0] Boom Angle Sensor Dislocation
  • Failure code [DKA1KA] Failure of Bucket Angle Sensor
  • Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit
  • Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
  • Failure code [DLF1LC] Failure of T/M Input Speed Sensor
  • Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor
  • Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
  • Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main)
  • Failure code [DLT3LC] Failure of Output Speed Sensor (Main)
  • Failure code [DPQ1KR] LIN Discon (Switch Panel)
  • Failure code [DPQ2KR] LIN Discon (LED Unit)
  • Failure code [DPQ3KR] LIN Discon (Rear View Monitor)
  • Failure code [DSJ0KR] CAN2 Discon (Meter Unit)
  • Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator
  • Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic
  • Failure code [DV00KB] Ground Fault of Buzzer Output
  • Failure code [DW2BKA] Disconnection of Main Flow Selector Sol
  • Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol
  • Failure code [DW2BKY] Hot Short of Main Flow Selector Sol
  • Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve
  • Failure code [DW2BLH] Malfunction of Main Flow Selector Valve
  • Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise)
  • Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise)
  • Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise)
  • Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower)
  • Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower)
  • Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower)
  • Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)
  • Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt)
  • Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)
  • Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump)
  • Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump)
  • Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump)
  • Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid
  • Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol
  • Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol
  • Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid
  • Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid
  • Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid
  • Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom)
  • Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom)
  • Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom)
  • Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket)
  • Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)
  • Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket)
  • Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol
  • Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol
  • Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol
  • Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid
  • Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid
  • Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid
  • Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward)
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward)
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)
Failure code [DXHLKA] Disconnection of J/S Right EPC Solenoid
Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid
Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid
Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid
Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid
Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid
Failure code [LA00L3] Failure of Fan Reverse
Troubleshooting of electrical system (E-mode)
Engine does not start (Engine does not crank)
Manual preheating system does not work
Automatic preheating system does not work
While preheating is working, preheating monitor does not light up
All of LCD unit, LED unit, and meter unit on machine monitor display nothing
LCD unit on machine monitor displays nothing
LCD on machine monitor does not display properly
Meter unit display on machine monitor is abnormal
Night lighting lamp of meter unit on machine monitor is abnormal
Caution LED on machine monitor is abnormal
Two switches operation of switch panel on machine monitor does not function
Switch panel buzzer of machine monitor is abnormal
Rearview monitor does not light up or backlight flickers
Rearview monitor images are not displayed clearly
Rearview monitor brightness cannot be adjusted
Night lighting lamp of rearview monitor is abnormal33 topics
  • Air cleaner clogging indicator lamp does not light
  • Radiator coolant level caution lamp does not light
  • Fuel level gauge does not indicate correct level
  • Seat belt caution lamp indication is abnormal
  • Horn does not sound
  • Horn does not stop sounding
  • Alarm buzzer does not sound
  • When starting switch is in ON position, alarm buzzer does not stop sounding
  • Kickdown does not work when kickdown switch is turned ON
  • The hold switch does not work when it is pressed
  • Transmission cut-off mode is not selected or not released
  • Transmission cut-off setting cannot be released
  • FNR switch mode is not selected or not released
  • Flow of loader pump does not increase from the minimum rate
  • ECSS function cannot be selected or cannot be released
  • None of headlamp, clearance lamp, and tail lamp lights
  • Clearance lamp and tail lamp do not light up or go out
  • Both High and Low beams of headlamp do not light up or go out
  • Low beam of headlamp does not light up or go out
  • High beam of headlamp does not light up or go out
  • Front working lamp does not light up or go out
  • Rear working lamp does not light up or go out
  • All of turn signal lamps and hazard lamps do not light up or go out
  • Turn signal lamps do not light up or go out
  • Hazard lamp does not light up or go out
  • Brake lamp does not light up or stays lighted
  • Backup lamp does not light or continues to light
  • Backup buzzer does not sound or continues to sound
  • Front wiper does not operate
  • Rear wiper does not operate
  • Window washer does not operate
  • Fuel feed pump does not operate or stop automatically
  • KOMTRAX system does not operate properly
Troubleshooting of hydraulic and mechanical system (H-mode)13 topics
  • Information described in troubleshooting table (H-mode)
  • System chart of hydraulic and mechanical systems
  • Failure mode and cause table
  • Machine does not start
  • Torque converter lockup clutch is not disengaged (engine stalls)
  • Torque converter lockup clutch is not engaged
  • Large shock is made when machine starts or gear is shifted
  • Machine starts or gear speed shifts with long time lag
  • Torque converter oil temperature is high
  • Machine does not turn
  • Turning response is poor
  • Steering wheel is heavy to turn
  • Machine sways or large shocks are made while machine turns
Turning radius differs between right and left turns
Wheel brakes do not work or are weak
Wheel brakes are not released or drag
Parking brake does not work or it is weak
Parking brake is not released or drags (including emergency release system)
Boom does not rise
Boom moves slow or boom lacks lifting force
Rising boom slows down at certain height
Lift cylinders do not serve to hold bucket on ground
Hydraulic drift of boom is large
Boom moves up and down during operation
Bucket does not tilt back
Bucket moves slow or bucket lacks tilt-back force
Bucket decelerates during tilt-back operation
Bucket cylinder does not hold bucket on ground
Hydraulic drift of bucket is large
Boom and bucket control levers do not move smoothly and are heavy to move
Large shocks are made when work equipment starts to move and stops
E.C.S.S. (travel damper) does not work and machine pitches and bounces
Fan speed is abnormal (too high or low, or fan does not rotate)
Unusual noise is heard from around fan
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
When starting switch is turned to START position, engine is not cranked
The engine cranks but exhaust smoke does not come out
Engine startability is poor
Engine does not pick-up smoothly
Engine stops during operation
Engine runs rough or is unstable
Engine lacks power
KDPF gets clogged in a short time
Engine oil consumption is excessive
Engine oil becomes contaminated early
Fuel consumption is excessive
Oil is in coolant (or coolant spurts or coolant level goes down)
Oil pressure drops
Fuel mixes into engine oil

Inside this manual

Real pages from this service manual (2,523 pages). Open the sample pages (PDF, 836 KB)

Sample pages from the Komatsu WA500-7 Wheel Loader Service Manual: Diagram, Troubleshooting, Specifications, Foldout diagram
  • Diagram, page 103: 10 Structure and function
  • Troubleshooting, page 1,585: Failure code [DSJ0KR] CAN2 Discon (Meter Unit)
  • Specifications, page 2,092: 50 Disassembly and assembly
  • Foldout diagram, page 2,491: Electrical circuit diagram (2/13)

Other manuals for this machine

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This manual: Service Manual SEN05693-04$259.61
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Details
Details

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, 2,523 pages

Quantity one is the manual described above.

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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 WA500-7 with 6D140E-6 EngineService Manual · CEBM026803 · $259.51

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