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Komatsu WA500-8 with 6D140E-7 Engine Wheel Loader Service Manual

3,731 pages · Publication CEBM030802

$379.83
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Models
WA500-8 with 6D140E-7 Engine
Serial coverage
A96001 and up
Manual type
Service Manual
Pages
3,731
Publication
CEBM030802
Condition
Brand new
Komatsu WA500-8 with 6D140E-7 Engine Wheel Loader Service Manual, publication CEBM030802

What's inside

From the manual's own table of contents: 373 sections, 700 entries. See sample pages (PDF, 1102 KB)

INDEX AND FOREWORD
ABBREVIATION LIST
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR DEF
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
HOW TO READ ELECTRICAL WIRE CODE
Show all 373 sections
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
SPECIFICATIONS
SPECIFICATION DRAWING
WEIGHT TABLE
TABLE OF FUEL, COOLANT, AND LUBRICANTS
STRUCTURE AND FUNCTION
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
PREHEATING SYSTEM
ENGINE SHUTDOWN SECONDARY SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
ENGINE POWER MODE SELECTOR SYSTEM
AUTOMATIC IDLE STOP SYSTEM2 topics
  • RPM SET
  • COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM3 topics
  • LAYOUT DRAWING OF COOLING SYSTEM
  • COOLING FAN CONTROL SYSTEM
  • COMPONENT PARTS OF COOLING SYSTEM
CONTROL SYSTEM6 topics
  • LAYOUT DRAWING OF CONTROL SYSTEM
  • MACHINE MONITOR SYSTEM
  • REARVIEW MONITOR SYSTEM
  • KOMTRAX SYSTEM
  • LOAD METER SYSTEM
  • COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM4 topics
  • LAYOUT DRAWING OF HYDRAULIC SYSTEM
  • CLSS
  • WORK EQUIPMENT PUMP CONTROL SYSTEM
  • COMPONENT PARTS OF HYDRAULIC SYSTEM
POWER TRAIN SYSTEM8 topics
  • LAYOUT DRAWING OF POWER TRAIN SYSTEM
  • OPERATION OF POWER TRAIN SYSTEM
  • TRANSMISSION CONTROL SYSTEM
  • TRANSMISSION GEAR SHIFT CONTROL SYSTEM
  • TRANSMISSION PROTECTION FUNCTION
  • DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION
  • TRANSMISSION CUT-OFF FUNCTION
  • COMPONENT PARTS OF POWER TRAIN SYSTEM
WORK EQUIPMENT SYSTEM9 topics
  • LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
  • WORK EQUIPMENT SYSTEM DIAGRAM
  • WORK EQUIPMENT CONTROL SYSTEM
  • WORK EQUIPMENT NEUTRAL LOCK SYSTEM
  • REMOTE POSITIONER SYSTEM
  • BUCKET POSITIONER AND BOOM POSITIONER
  • SYSTEM
  • ECSS
  • COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
STEERING SYSTEM6 topics
  • LAYOUT DRAWING OF STEERING SYSTEM
  • SECONDARY STEERING SYSTEM
  • JOYSTICK STEERING SYSTEM
  • AJSS
  • STEERING COLUMN
  • COMPONENT PARTS OF STEERING SYSTEM
BRAKE SYSTEM7 topics
  • LAYOUT DRAWING OF BRAKE SYSTEM
  • PARKING BRAKE CONTROL SYSTEM
  • COMPONENT PARTS OF BRAKE SYSTEM
  • LAYOUT DRAWING OF AUTO-GREASING SYSTEM
  • SPECIFICATIONS OF AUTO-GREASING SYSTEM
  • FUNCTION OF AUTO-GREASING SYSTEM
  • COMPONENT PARTS OF AUTO-GREASING SYSTEM
UNDERCARRIAGE AND FRAME2 topics
  • FRAME, AXLE MOUNT AND CENTER HINGE PIN
  • TIRE
WORK EQUIPMENT1 topic
  • STRUCTURE OF WORK EQUIPMENT
STRUCTURE OF BUCKET
STRUCTURE OF WORK EQUIPMENT LUBRICATION
CAB AND ITS ATTACHMENTS
ROPS CAB
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: WA500-8
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: WA500-8
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE
TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSURE
TESTING EXHAUST GAS TEMPERATURE
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST EGR VALVE AND VGT OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL RETURN RATE AND LEAKAGE
BLEEDING AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUT-OUT MODE OPERATION
HANDLE NO-INJECTION CRANKING OPERATION
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS
CLEAN FUEL DOSER
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
TEST SCR RELATED FUNCTIONS
CLEAN AdBlue/DEF TANK
POWER TRAIN
TEST AND ADJUST POWER TRAIN OIL PRESSURE
ADJUST TRANSMISSION INPUT SPEED SENSOR
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE
TEST STEERING WHEEL
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE
BLEED AIR FROM STEERING CYLINDER CIRCUIT
TEST AND ADJUST STEERING STOP VALVE
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
TEST WHEEL BRAKE OIL PRESSURE
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE30 topics
  • TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE
  • TEST BRAKING PERFORMANCE
  • TEST BRAKE PEDAL
  • BLEED AIR FROM BRAKE CIRCUIT
  • TEST AND ADJUST BRAKE PEDAL AND LINKAGE
  • ADJUST LEFT BRAKE PEDAL OPERATION SWITCH
  • TEST LOWERING OF WHEEL BRAKE PRESSURE
  • TEST WEAR OF WHEEL BRAKE DISC
  • TEST PARKING BRAKE OIL PRESSURE
  • TEST PARKING BRAKE PERFORMANCE
  • RELEASE PARKING BRAKE MANUALLY
  • TEST WEAR AMOUNT OF PARKING BRAKE DISC
  • RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT
  • TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE
  • TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE
  • BLEED AIR FROM WORK EQUIPMENT CIRCUIT
  • TEST COOLING FAN SPEED
  • TEST COOLING FAN CIRCUIT OIL PRESSURE
  • BLEED AIR FROM COOLING FAN CIRCUIT
  • NITROGEN GAS
  • TEST AND ADJUST BUCKET POTENTIOMETER LEVER
  • TEST AND ADJUST BOOM POTENTIOMETER LEVER
  • TEST DIRECTIONAL LEVER
  • TEST WORK EQUIPMENT CONTROL LEVER
  • TEST MULTIFUNCTION MONO-LEVER
  • TEST AJSS LEVER (FOR AJSS SPEC)
  • TEST STEERING LOCK LEVER
  • TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC)
  • TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC)
  • ADJUST RATTLING OPERATOR'S SEAT
ELECTRICAL SYSTEM7 topics
  • SET AND ADJUST EACH EQUIPMENT
  • SET AND OPERATE MACHINE MONITOR
  • METHOD FOR STARTING UP KOMTRAX TERMINAL
  • ADJUST REARVIEW CAMERA ANGLE
  • HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
  • HANDLE BATTERY DISCONNECT SWITCH
  • TEST DIODES
DEVICE2 topics
  • BLEED THE AIR OF AUTO-GREASING SYSTEM
  • CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES
Pm CLINIC1 topic
  • Pm CLINIC SERVICE
TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING7 topics
  • GENERAL TROUBLESHOOTING POINTS
  • TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
  • SEQUENCE OF EVENTS IN TROUBLESHOOTING
  • CHECKS BEFORE TROUBLESHOOTING
  • INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
  • TESTING IN ACCORDANCE WITH TESTING PROCEDURE
  • ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
CONNECTORS LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
FAILURE CODE [1500L0]
FAILURE CODE [15B0NX]
FAILURE CODE [15SAL1]
FAILURE CODE [15SALH]
FAILURE CODE [15SBL1]
FAILURE CODE [15SBLH]
FAILURE CODE [15SEL1]
FAILURE CODE [15SELH]
FAILURE CODE [15SFL1]
FAILURE CODE [15SFLH]
FAILURE CODE [15SGL1]
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FAILURE CODE [15SHL1]
FAILURE CODE [15SHLH]
FAILURE CODE [2F00MA]
FAILURE CODE [2F00MB]
FAILURE CODE [2G42ZG]
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FAILURE CODE [879AKA]
FAILURE CODE [879AKB]
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FAILURE CODE [879BKB]
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FAILURE CODE [AS00R2]
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FAILURE CODE [AS00R5]
FAILURE CODE [AS00R6]
FAILURE CODE [AS00ZK]58 topics
  • FAILURE CODE [AS10KM]
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  • FAILURE CODE [AS10NT]
  • FAILURE CODE [B@BAZG]
  • FAILURE CODE [B@BCNS]
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FAILURE CODE [CA2381]58 topics
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FAILURE CODE [CA4261]
FAILURE CODE [CA4277]58 topics
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  • FAILURE CODE [DAF0MB]
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  • FAILURE CODE [DAF3KK]
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  • FAILURE CODE [DAFGMC]
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FAILURE CODE [DAQ4KB]
FAILURE CODE [DAQ9KQ]
FAILURE CODE [DAQLKA]
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FAILURE CODE [DAQQKR]
FAILURE CODE [DAQRKR]
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FAILURE CODE [DB2RKR]
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FAILURE CODE [DB90KT]
FAILURE CODE [DB90MC]
FAILURE CODE [DB91KA]
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FAILURE CODE [DB95KX]
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FAILURE CODE [DB99KQ]
FAILURE CODE [DB9LKA]
FAILURE CODE [DB9LKB]
FAILURE CODE [DB9QKR]
FAILURE CODE [DB9RKR]
FAILURE CODE [DB9RMA]
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FAILURE CODE [DBE6KX]
FAILURE CODE [DD1ALD]
FAILURE CODE [DDA8KY]
FAILURE CODE [DDA9KY]
FAILURE CODE [DDAAL6]
FAILURE CODE [DDB6L4]
FAILURE CODE [DDD1LD]
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FAILURE CODE [DDK3KA]
FAILURE CODE [DDK3KB]
FAILURE CODE [DDK4KA]
FAILURE CODE [DDK4KB]
FAILURE CODE [DDK5L4]
FAILURE CODE [DDK6KA]
FAILURE CODE [DDK6KB]
FAILURE CODE [DDKLKA]
FAILURE CODE [DDKLKB]
FAILURE CODE [DDNRKY]
FAILURE CODE [DDP5KA]
FAILURE CODE [DDT0L4]
FAILURE CODE [DDT4LD]
FAILURE CODE [DDT9LD]
FAILURE CODE [DDTALD]
FAILURE CODE [DDW9LD]
FAILURE CODE [DDWLLD]
FAILURE CODE [DF10KA]
FAILURE CODE [DF10KB]
FAILURE CODE [DGF1KA]
FAILURE CODE [DGF1KB]
FAILURE CODE [DGH2KX]
FAILURE CODE [DGR2KB]
FAILURE CODE [DGR2KZ]
FAILURE CODE [DGT1KA]58 topics
  • FAILURE CODE [DGT1KB]
  • FAILURE CODE [DH21KA]
  • FAILURE CODE [DH21KB]
  • FAILURE CODE [DHA4KA]
  • FAILURE CODE [DHAAMA]
  • FAILURE CODE [DHACMA]
  • FAILURE CODE [DHPCKX]
  • FAILURE CODE [DHPDKX]
  • FAILURE CODE [DHQ2KX]
  • FAILURE CODE [DHT1KX]
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  • FAILURE CODE [DHT5KX]
  • FAILURE CODE [DHT7KX]
  • FAILURE CODE [DHT8KA]
  • FAILURE CODE [DHT8KB]
  • FAILURE CODE [DHT8ZG]
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  • FAILURE CODE [DK30KY]
  • FAILURE CODE [DK55KA]
  • FAILURE CODE [DK55KY]
  • FAILURE CODE [DK55L5]
  • FAILURE CODE [DK59KA]
  • FAILURE CODE [DK59KY]
  • FAILURE CODE [DK59L8]
  • FAILURE CODE [DK5AKA]
  • FAILURE CODE [DK5AKY]
  • FAILURE CODE [DK5BKA]
  • FAILURE CODE [DK5BKY]
  • FAILURE CODE [DK5BL8]
  • FAILURE CODE [DK5CKA]
  • FAILURE CODE [DK5CKY]
  • FAILURE CODE [DK5DKA]
  • FAILURE CODE [DK5DKY]
  • FAILURE CODE [DK5DL8]
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  • FAILURE CODE [DK5FL8]
  • FAILURE CODE [DK5GKA]
  • FAILURE CODE [DK5GKY]
  • FAILURE CODE [DKA0KA]
  • FAILURE CODE [DKA0KY]
  • FAILURE CODE [DKA0L0]
  • FAILURE CODE [DKA1KA]
  • FAILURE CODE [DKA1KY]
  • FAILURE CODE [DKD0KA]
  • FAILURE CODE [DKD0KY]
  • FAILURE CODE [DKD0L8]
  • FAILURE CODE [DLF1KA]
  • FAILURE CODE [DLF1LC]
  • FAILURE CODE [DLM3KA]
  • FAILURE CODE [DLM3LC]
  • FAILURE CODE [DLT3KA]
  • FAILURE CODE [DLT3LC]
  • FAILURE CODE [DPQ1KR]
  • FAILURE CODE [DPQ2KR]
FAILURE CODE [DPQ3KR]
FAILURE CODE [DSJ0KR]
FAILURE CODE [DT20KB]
FAILURE CODE [DT22KB]
FAILURE CODE [DT23KB]
FAILURE CODE [DV00KB]
FAILURE CODE [DW2BKA]
FAILURE CODE [DW2BKB]
FAILURE CODE [DW2BKY]
FAILURE CODE [DW2BL1]
FAILURE CODE [DW2BLH]
FAILURE CODE [DW4PKA]
FAILURE CODE [DW4PKB]
FAILURE CODE [DW4PKY]
FAILURE CODE [DW4QKA]
FAILURE CODE [DW4QKB]
FAILURE CODE [DW4QKY]
FAILURE CODE [DW4RKA]
FAILURE CODE [DW4RKB]
FAILURE CODE [DW4RKY]
FAILURE CODE [DW4SKA]
FAILURE CODE [DW4SKB]
FAILURE CODE [DW4SKY]
FAILURE CODE [DW7BKA]
FAILURE CODE [DW7BKB]
FAILURE CODE [DW7BKY]
FAILURE CODE [DWM1KA]
FAILURE CODE [DWM1KB]
FAILURE CODE [DWM1KY]

Inside this manual

Real pages from this service manual (3,731 pages). Open the sample pages (PDF, 1101 KB)

Sample pages from the Komatsu WA500-8 with 6D140E-7 Engine Wheel Loader Service Manual: Diagram, Troubleshooting, Specifications, Color page, Color page, Foldout diagram
  • Diagram, page 1,235: Circuit diagram related to outside air temperature sensor electrical circuit
  • Troubleshooting, page 1,691: FAILURE CODE [CA3596]
  • Specifications, page 2,603: Procedure, measuring location, criteria and remarks
  • Color page, page 204: COOLING SYSTEM
  • Color page, page 3,492: STEERING SYSTEM
  • Foldout diagram, page 3,696: ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (2/8)

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, 3,731 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 WA500-8Operation & Maintenance Manual · CEAM030702 · $69.57Komatsu WA500-8Operation & Maintenance Manual · TEN00713-04 · $69.69Komatsu WA500-8Service Manual · SEN06581-07 · $379.55

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).