Komatsu ecot3 WA600-6 Shop Manual
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Komatsu ecot3 WA600-6 Shop Manual

Komatsu ecot3 WA600-6 Shop Manual

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SEN00235-18
WHEEL LOADER
WA600
-6
60001
SERIAL NUMBERS
and up

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  • Page 1 SEN00235-18 WHEEL LOADER WA600 60001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SEN00398-18 WHEEL LOADER 1SHOP MANUAL WA600-6 Machine model Serial number WA600-6 60001 and up 00 Index and foreword Index Composition of shop manual .......................... 2 Table of contents ............................. 4 WA600-6 Find manuals at https://best-manuals.com...
  • Page 4 SEN00398-18 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
  • Page 5 00 Index and foreword SEN00398-18 SEN00558-03 q Troubleshooting by failure code (Display of code), Part 1 SEN00559-04 q Troubleshooting by failure code (Display of code), Part 2 SEN00560-03 q Troubleshooting by failure code (Display of code), Part 3 SEN00561-04 q Troubleshooting by failure code (Display of code), Part 4 SEN00562-04 q Troubleshooting by failure code (Display of code), Part 5...
  • Page 6 SEN00398-18 00 Index and foreword Table of contents 00 Index and foreword Index SEN00398-18 Composition of shop manual ....................Table of contents........................Foreword and general information SEN00415-04 Safety notice ..........................How to read the shop manual....................Explanation of terms for maintenance standard ..............Handling of electric equipment and hydraulic component ............
  • Page 7 00 Index and foreword SEN00398-18 Final drive ..........................28 Steering system SEN00404-03 Steering system........................... Steering piping diagram......................Steering column........................Joystick steering lever linkage....................Joystick EPC valve ........................Lock valve..........................Steering valve .......................... 10 Rotary valve..........................13 Steering control valve ......................16 Two-way restrictor valve ......................
  • Page 8 SEN00398-18 00 Index and foreword Cab and its attachments SEN00409-01 Cab and its attachments......................ROPS cab..........................Air conditioner.......................... Electrical system, Part 1 SEN01009-02 Electrical system, Part 1......................Machine monitor system......................Machine monitor ........................Electrical system, Part 2 SEN00410-02 Electrical system, Part 2......................Work equipment control system ....................
  • Page 9 00 Index and foreword SEN00398-18 Testing and adjusting, Part 2 SEN00554-06 Measuring operating effort of AJSS lever (AJSS specification)..........Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) Testing and adjusting steering stopper bolt (AJSS specification) ..........Testing and adjusting steering wheel (Steering wheel specification)........
  • Page 10 SEN00398-18 00 Index and foreword T- branch box and T- branch adapter table................54 Troubleshooting by failure code (Display of code), Part 1 SEN00558-03 Failure code [1500L0] TORQFLOW transmission: Double meshing ........Failure code [15B0NX] Transmission Oil Filter Clogging............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..
  • Page 11 00 Index and foreword SEN00398-18 Failure code [CA271] PCV1 Short circuit ................10 Failure code [CA272] PCV1 Disconnection................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 ..............
  • Page 12 SEN00398-18 00 Index and foreword Failure code [D5ZHKZ] Terminal C signal open or short circuit..........36 Failure code [D5ZHL6] Terminal C signal: Signal does not match engine running or stopped state ........................38 Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal..... 40 Failure code [DAF3KK] Machine monitor: Source voltage low (input) ........
  • Page 13 00 Index and foreword SEN00398-18 Failure code [DD1GLD] (Load meter mode selector switch (+/–): Switch is kept pressed for long time)....................... 50 Troubleshooting by failure code (Display of code), Part 6 SEN00569-04 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) ........................
  • Page 14 SEN00398-18 00 Index and foreword Failure code [DHT8KX] (or VHMS_LED display: “n5” o “33”) (Steering oil pressure sensor: Out of input signal range) ....................42 Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection ...... 46 Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit ......48 Failure code [DHU2KX] (or VHMS_LED display: “n7”...
  • Page 15 00 Index and foreword SEN00398-18 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..........
  • Page 16 SEN00398-18 00 Index and foreword Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection..........22 Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit ..........24 Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line ... 26 Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection ........
  • Page 17 00 Index and foreword SEN00398-18 H-10 Turning, response of steering is poor [machine with steering wheel] ......23 H-11 Turning, response of AJSS is poor [machine with AJSS] ..........24 H-12 Steering is heavy [machine with steering wheel] ............25 H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel] .
  • Page 18 SEN00398-18 00 Index and foreword Removal and installation of cooling fan and fan motor assembly..........12 Removal and installation of damper assembly ................ 14 Disassembly and assembly of damper assembly..............16 Removal and installation of fuel tank assembly ............... 20 Removal and installation of engine hood assembly..............
  • Page 19 00 Index and foreword SEN00398-18 Electrical system SEN01177-03 Removal and installation of engine controller assembly............Removal and installation of transmission controller assembly ..........Removal and installation of loader controller assembly ............Removal and installation of VHMS controller assembly ............Removal and installation of monitor assembly ................ 90 Diagrams and drawings Hydraulic diagrams and drawings SEN00412-04...
  • Page 20 SEN00398-18 WA600-6 Wheel loader Form No. SEN00398-18 © 2017 KOMATSU All Rights Reserved Printed in Japan 03-17 (01)

  • Page 21: Table Of Contents

    SEN00415-04 WHEEL LOADER 1SHOP MANUAL WA600-6 Machine model Serial number WA600-6 60001 and up 00 Index and foreword Foreword and general information 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 ...................

  • Page 22: Safety Notice

    Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
  • Page 23 00 Index and foreword SEN00415-04 Preparations for work Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground.
  • Page 24 SEN00415-04 00 Index and foreword 12) When assembling or installing parts, 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.
  • Page 25 00 Index and foreword SEN00415-04 Precautions for using overhead hoist crane When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disas- sembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over...
  • Page 26 SEN00415-04 00 Index and foreword Selecting wire ropes Connection Select adequate ropes depending on the When installing the air conditioner cir- weight of parts to be hoisted, referring to cuit hoses and tubes, take care that the table below. dirt, dust, water, etc. will not enter them.

  • Page 27: How To Read The Shop Manual

    Engine volume This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. WA600-6...
  • Page 28 SEN00415-04 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.

  • Page 29: Explanation Of Terms For Maintenance Standard

    00 Index and foreword SEN00415-04 Explanation of terms for maintenance standard 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. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
  • Page 30 SEN00415-04 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.

  • Page 31: Handling Of Electric Equipment And Hydraulic Component

    00 Index and foreword SEN00415-04 Handling of electric equipment and hydraulic component 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.
  • Page 32 SEN00415-04 00 Index and foreword 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.
  • Page 33 00 Index and foreword SEN00415-04 Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
  • Page 34 SEN00415-04 00 Index and foreword Connecting connectors 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.
  • Page 35 00 Index and foreword SEN00415-04 Heavy duty wire connector (DT 8-pole, 12- Disconnection 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) Push in female connector (2) horizon- tally until the lock clicks.
  • Page 36 SEN00415-04 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
  • Page 37 00 Index and foreword SEN00415-04 Handling controller 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. Do not place objects on top of the control- ler.
  • Page 38 SEN00415-04 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
  • Page 39 00 Index and foreword SEN00415-04 Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.

  • Page 40: Handling Of Connectors Newly Used For Engines

    SEN00415-04 00 Index and foreword Handling of connectors newly used for engines Pull lock type (PACKARD-2) a Mainly, following engines are object for follow- ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example) 114E-3 Intake air temperature sensor in 125E-5 intake manifold: TIM 140E-5...
  • Page 41 00 Index and foreword SEN00415-04 Push lock type 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engines Example)
  • Page 42 SEN00415-04 00 Index and foreword Turn-housing type (Round green connector) 95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, 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.

  • Page 43: How To Read Electric Wire Code

    00 Index and foreword SEN00415-04 How to read electric wire code 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.
  • Page 44 SEN00415-04 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 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...
  • Page 45 00 Index and foreword SEN00415-04 Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...

  • Page 46: Precautions When Carrying Out Operation

    SEN00415-04 00 Index and foreword 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.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.
  • Page 47 00 Index and foreword SEN00415-04 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
  • Page 48 SEN00415-04 00 Index and foreword Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.

  • Page 49: Method Of Disassembling And Connecting Push-Pull Type Coupler

    00 Index and foreword SEN00415-04 Method of disassembling and connecting push-pull type coupler 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. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
  • Page 50 SEN00415-04 00 Index and foreword Type 2 Disconnection 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) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
  • Page 51 00 Index and foreword SEN00415-04 Type 3 Disconnection 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) 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.

  • Page 52: Standard Tightening Torque Table

    SEN00415-04 00 Index and foreword Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque...
  • Page 53 00 Index and foreword SEN00415-04 Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 – 74 6.0 – 7.5 98 –...
  • Page 54 SEN00415-04 00 Index and foreword 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. Tightening torque Nm {kgm} Taper seal Face seal...
  • Page 55 00 Index and foreword SEN00415-04 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. Thread size Tightening torque 8 ±...

  • Page 56: Conversion Table

    SEN00415-04 00 Index and foreword Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches.
  • Page 57 00 Index and foreword SEN00415-04 Millimeters to inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181...
  • Page 58 SEN00415-04 00 Index and foreword Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379...
  • Page 59 00 Index and foreword SEN00415-04 kg/cm to lb/in 1 kg/cm = 14.2233 lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
  • Page 60 SEN00415-04 00 Index and foreword 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.
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