WHEEL LOADER SEN00235-05 WA600 -6 SERIAL NUMBERS 60001 and up
WA600-6 1 SEN00398-05 WHEEL LOADER 1SHOP MANUAL WA600-6 Machine model Serial number WA600-6 60001 and up 00 Index and foreword 1 Index Composition of shop manual ................................................................................................................ 2 Table of contents .................................................................................................................................. 4
SEN00398-05 00 Index and foreword 2 WA600-6 Composition of shop manual 1 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. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accord- ingly. Section Title Form Number Shop Manual, contents binder, binder label and tabs SEN00235-05 00 Index and foreword SEN00397-05 Index SEN00398-05 q Foreword and general information SEN00415-01 01 Specification SEN00399-02 Specification and technical data SEN00400-02 q 10 Structure, function and maintenance standard SEN00401-02 Engine and cooling system SEN00402-01 q Power train, Part 1 SEN00403-02 q Power train, Part 2 SEN02455-00 Q Steering system SEN00404-01 q Brake system SEN00405-01 q Undercarriage and frame SEN00406-00 Hydraulic system, Part 1 SEN00407-01 q Hydraulic system, Part 2 SEN02456-00 Q Work equipment SEN00408-01 q Cab and its attachments SEN00409-01 q Electrical system, Part 1 SEN01009-01 q Electrical system, Part 2 SEN00410-02 q Electrical system, Part 3 SEN00411-02 q 20 Standard value table SEN00566-01 Standard service value table SEN00552-01 q 30 Testing and adjusting SEN00567-01 Testing and adjusting, Part 1 SEN00553-01 q Testing and adjusting, Part 2 SEN00554-01 q Testing and adjusting, Part 3 SEN00555-01 q Testing and adjusting, Part 4 SEN00556-01 q 40 Troubleshooting SEN00568-01 General information on troubleshooting SEN00557-00 Troubleshooting by failure code (Display of code), Part 1 SEN00558-01 q
00 Index and foreword SEN00398-05 WA600-6 3 Troubleshooting by failure code (Display of code), Part 2 SEN00559-01 q Troubleshooting by failure code (Display of code), Part 3 SEN00560-00 Troubleshooting by failure code (Display of code), Part 4 SEN00561-01 q Troubleshooting by failure code (Display of code), Part 5 SEN00562-01 q Troubleshooting by failure code (Display of code), Part 6 SEN00569-01 q Troubleshooting by failure code (Display of code), Part 7 SEN00570-01 q Troubleshooting by failure code (Display of code), Part 8 SEN00571-01 q Troubleshooting by failure code (Display of code), Part 9 SEN00572-01 q Troubleshooting by failure code (Display of code), Part 10 SEN00573-01 q Troubleshooting by failure code (Display of code), Part 11 SEN00574-01 q Troubleshooting of electrical system (E-mode) SEN00563-01 q Troubleshooting of hydraulic and mechanical system (H-mode) SEN00564-00 Troubleshooting of engine (S-mode) SEN00565-00 50 Disassembly and assembly SEN00583-01 General information on disassembly and assembly SEN01156-01 Engine and cooling system, Part 1 SEN01157-00 Engine and cooling system, Part 2 SEN01158-00 Power train, Part 1 SEN01160-00 Power train, Part 2 SEN01162-00 Power train, Part 3 SEN01164-00 Power train, Part 4 SEN01165-00 Brake system SEN01167-00 Undercarriage and frame SEN01169-00 Hydraulic system SEN01171-00 Work equipment SEN01174-00 Cab and its attachments SEN01175-00 Electrical system SEN01177-00 90 Diagrams and drawings SEN00414-03 Hydraulic diagrams and drawings SEN00412-02 q Electrical diagrams and drawings SEN00413-02 q
SEN00398-05 00 Index and foreword 4 WA600-6 Table of contents 1 00 Index and foreword Index SEN00398-05 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information SEN00415-01 Safety notice ............................................................................................................................ 2 How to read the shop manual .................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling electric equipment and hydraulic component ........................................................... 11 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table .............................................................................................. 32 Conversion table ...................................................................................................................... 36 01 Specification Specification and technical data SEN00400-02 Specification and technical data .................................................................................................. 2 Specification dimension drawing.............................................................................................. 2 Specifications ........................................................................................................................... 3 Weight table ............................................................................................................................. 10 Table of fuel, coolant and lubricants ........................................................................................ 12 10 Structure, function and maintenance standard Engine and cooling system SEN00402-01 Engine and cooling system ......................................................................................................... 2 Engine mount and transmission mount ................................................................................... 2 Cooling system ........................................................................................................................ 6 Cooling fan pump..................................................................................................................... 10 Cooling fan motor .................................................................................................................... 18 Power train, Part 1 SEN00403-02 Power train, Part 1....................................................................................................................... 2 Power train............................................................................................................................... 2 Power train system diagram .................................................................................................... 3 Torque converter and transmission piping diagram ................................................................. 4 Torque converter ...................................................................................................................... 6 Modulation clutch ..................................................................................................................... 15 Torque converter regulator valve ............................................................................................. 16 Transmission............................................................................................................................ 18 Transfer.................................................................................................................................... 38 Transmission control valve ...................................................................................................... 40 ECMV ...................................................................................................................................... 43 Main relief valve and torque converter relief valve .................................................................. 50 Lubrication relief valve ............................................................................................................. 52 Power train, Part 2 SEN02455-00 Power train, Part 2....................................................................................................................... 2 Torque converter oil cooler ...................................................................................................... 2 Torque converter oil filter ......................................................................................................... 3 Drive shaft ................................................................................................................................ 5 Center support ......................................................................................................................... 6 Axle .......................................................................................................................................... 8 Differential ................................................................................................................................ 12 Limited slip differential ............................................................................................................. 21 Final drive ................................................................................................................................ 26
00 Index and foreword SEN00398-05 WA600-6 5 Steering system SEN00404-01 Steering system........................................................................................................................... 4 Steering piping diagram........................................................................................................... 4 Steering column ....................................................................................................................... 6 Joystick steering lever linkage ................................................................................................. 7 Joystick EPC valve .................................................................................................................. 8 Lock valve................................................................................................................................ 9 Steering valve .......................................................................................................................... 10 Rotary valve............................................................................................................................. 13 Steering control valve .............................................................................................................. 16 Two-way restrictor valve .......................................................................................................... 32 Stop valve ................................................................................................................................ 33 Steering pump ......................................................................................................................... 34 Steering cylinder ...................................................................................................................... 48 Emergency steering piping diagram ........................................................................................ 49 Diverter valve........................................................................................................................... 50 Emergency steering pump....................................................................................................... 58 Brake system SEN00405-01 Brake system .............................................................................................................................. 2 Brake piping diagram............................................................................................................... 2 Brake ....................................................................................................................................... 4 Brake valve .............................................................................................................................. 8 Accumulator charge valve ....................................................................................................... 16 EPC relief valve ....................................................................................................................... 22 Accumulator (for brake) ........................................................................................................... 24 Slack adjuster .......................................................................................................................... 26 Parking brake .......................................................................................................................... 30 Parking brake solenoid valve................................................................................................... 32 Emergency parking brake release valve ................................................................................. 34 Brake cooling pump ................................................................................................................. 35 Undercarriage and frame SEN00406-00 Undercarriage and frame ............................................................................................................ 2 Axle mount ............................................................................................................................... 2 Center hinge pin ...................................................................................................................... 7 Hydraulic system, Part 1 SEN00407-01 Hydraulic system, Part 1 ............................................................................................................. 2 Hydraulic piping diagram ......................................................................................................... 2 Work equipment control lever linkage ..................................................................................... 4 Hydraulic tank .......................................................................................................................... 6 Work equipment hydraulic pump ............................................................................................. 8 Hydraulic system, Part 2 SEN02456-00 Hydraulic system, Part 2 ............................................................................................................. 2 Control valve............................................................................................................................ 2 CLSS ....................................................................................................................................... 16 Each function and operation of each valve.............................................................................. 21 Accumulator (for PPC circuit) .................................................................................................. 36 Triple pump .............................................................................................................................. 37 Work equipment SEN00408-01 Work equipment .......................................................................................................................... 2 Work equipment linkage .......................................................................................................... 2 Bucket...................................................................................................................................... 6 Bucket positioner and boom kick-out ....................................................................................... 8 Work equipment lubrication ..................................................................................................... 9 Cab and its attachments SEN00409-01 Cab and its attachments.............................................................................................................. 2 ROPS cab................................................................................................................................ 2
SEN00398-05 00 Index and foreword 6 WA600-6 Air conditioner .......................................................................................................................... 4 Electrical system, Part 1 SEN01009-01 Electrical system, Part 1 .............................................................................................................. 2 Machine monitor system.......................................................................................................... 2 Machine monitor ...................................................................................................................... 8 Electrical system, Part 2 SEN00410-02 Electrical system, Part 2 .............................................................................................................. 2 Work equipment control system .............................................................................................. 2 Transmission controller system ............................................................................................... 38 Electrical system, Part 3 SEN00411-02 Electrical system, Part 3 .............................................................................................................. 2 Electric transmission control .................................................................................................... 2 Engine starting/stopping circuit ................................................................................................ 4 Parking brake circuit ................................................................................................................ 7 Sensor ..................................................................................................................................... 11 VHMS controller related........................................................................................................... 33 Work equipment electric lever ................................................................................................. 37 20 Standard value table Standard service value table SEN00552-01 Standard service value table ....................................................................................................... 2 Standard service value table for engine................................................................................... 2 Standard service value table for chassis ................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN00553-01 Testing and adjusting, Part 1 ....................................................................................................... 3 Tools for testing, adjusting, and troubleshooting...................................................................... 3 Measuring engine speed ......................................................................................................... 6 Measuring exhaust gas color ................................................................................................... 8 Measuring exhaust temperature .............................................................................................. 9 Adjusting valve clearance ........................................................................................................ 11 Testing compression pressures ............................................................................................... 13 Measuring blow-by pressure.................................................................................................... 16 Measuring engine oil pressure................................................................................................. 17 Measuring intake air (boost) pressure ..................................................................................... 18 Handling fuel system equipment.............................................................................................. 19 Releasing residual pressure in fuel system ............................................................................. 19 Testing fuel pressures .............................................................................................................. 20 Testing return rate and leakage ............................................................................................... 21 Bleeding air from fuel circuit .................................................................................................... 24 Testing leakage in fuel system................................................................................................. 25 Handling reduced cylinder mode operation ............................................................................. 26 Handling no-injection cranking operation................................................................................. 26 Handling controller voltage circuit ............................................................................................ 27 Replacing and adjusting alternator and air conditioner compressor belt tension .................... 28 Adjusting modulation clutch speed sensor and speed sensor ................................................. 29 Measuring directional lever (Steering wheel specification) ...................................................... 31 Testing and adjusting power train oil pressure......................................................................... 32 Flushing procedure for torque converter and transmission hydraulic circuit ............................ 46 Method of moving machine when transmission valve is broken .............................................. 48 Adjusting steering stop valve ................................................................................................... 50 Testing and adjusting, Part 2 SEN00554-01 Testing and adjusting, Part 2 ....................................................................................................... 3 Measuring operating effort of AJSS lever (AJSS specification) ............................................... 3 Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) 4
00 Index and foreword SEN00398-05 WA600-6 7 Testing and adjusting steering stopper bolt (AJSS specification) ............................................ 6 Testing and adjusting steering wheel (Steering wheel specification) ....................................... 8 Testing steering oil pressure .................................................................................................... 10 Bleeding air from steering cylinder circuit ................................................................................ 14 Testing hydraulic drive fan ....................................................................................................... 15 Bleeding air from hydraulic drive fan circuit ............................................................................. 18 Measuring brake pedal ............................................................................................................ 20 Measuring brake performance................................................................................................. 21 Testing and adjusting accumulator charge pressure ............................................................... 22 Testing wheel brake oil pressure ............................................................................................. 24 Measuring wear of wheel brake disc ....................................................................................... 26 Bleeding air from wheel brake circuit ....................................................................................... 27 Releasing residual pressure in brake accumulator circuit ....................................................... 28 Testing parking brake performance ......................................................................................... 29 Measuring parking brake oil pressure ..................................................................................... 30 Testing wear of parking brake disc .......................................................................................... 33 Method of releasing parking brake manually ........................................................................... 34 Measuring and adjusting work equipment control lever .......................................................... 35 Measuring work equipment oil pressure .................................................................................. 36 Bleeding air from work equipment circuit ................................................................................. 41 Releasing residual pressure in work equipment circuit ........................................................... 42 Moving machine for removing operator cab ............................................................................ 43 Testing and adjusting bucket positioner................................................................................... 45 Testing and adjusting lift arm position detecting lever ............................................................. 47 Checking proximity switch operation indication lamp .............................................................. 48 Preparations for work on troubleshooting of electric system ................................................... 49 Procedure for testing diodes.................................................................................................... 53 Testing and adjusting, Part 3 SEN00555-01 Testing and adjusting, Part 3 ....................................................................................................... 2 Special functions of machine monitor (EMMS) ........................................................................ 4 Testing and adjusting, Part 4 SEN00556-01 Testing and adjusting, Part 4 ....................................................................................................... 2 Special functions of machine monitor (EMMS) ........................................................................ 2 VHMS controller initial setting procedure ................................................................................ 15 Precautions for replacing VHMS controller.............................................................................. 35 Pm-click inspection table ......................................................................................................... 41 40 Troubleshooting General information on troubleshooting SEN00557-00 General information on troubleshooting ...................................................................................... 2 Points to remember when troubleshooting .............................................................................. 2 Sequence of events in troubleshooting ................................................................................... 3 Testing before troubleshooting ................................................................................................ 4 Classification and procedures of troubleshooting .................................................................... 5 Connection table for connector pin numbers ........................................................................... 8 T-branch box and T-branch adapter table ............................................................................... 31 Troubleshooting by failure code (Display of code), Part 1 SEN00558-01 Troubleshooting by failure code (Display of code), Part 1........................................................... 3 Failure codes list ...................................................................................................................... 3 Before carrying out troubleshooting for electrical system ........................................................ 16 Information contained in troubleshooting table ........................................................................ 18 Failure code [1500L0] (TORQFLOW transmission : Double meshing).................................... 20 Failure code [15B0NX] (Transmission filter: Clogged)............................................................. 22 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) .... 24 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) ... 26 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) .... 28 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)... 30
SEN00398-05 00 Index and foreword 8 WA600-6 Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON) ............ 32 Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF) ........... 34 Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON) ............. 36 Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF) ............ 38 Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON) ............ 40 Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF) ........... 42 Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON) ............ 44 Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF) ........... 46 Failure code [15W0NT] (Transmission modulation clutch: Overheating)................................. 48 Failure code [2F00MA] (Parking brake: Malfunction) .............................................................. 49 Failure code [2G42ZG] (Front accumulator: Low oil pressure)................................................ 52 Troubleshooting by failure code (Display of code), Part 2 SEN00559-01 Troubleshooting by failure code (Display of code), Part 2 ........................................................... 4 Failure code [2G43ZG] (Rear accumulator: Low oil pressure) ................................................ 4 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) .................................... 6 Failure code [A000N1] (or VHMS_LED display: “n2” o “01”) (Engine: Overrun) .................... 8 Failure code [AA1ANX] (Air cleaner: Clogging) ....................................................................... 10 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) .............. 12 Failure code [AB00MA] (Alternator: Malfunction) .................................................................... 14 Failure code [B@BAZG] (Rotation derating by low engine oil pressure) ................................. 16 Failure code [B@BAZK] (Engine oil: Low level) ...................................................................... 18 Failure code [B@BCNS] (Engine overheating)........................................................................ 20 Failure code [B@BCZK] (Coolant: Low level).......................................................................... 22 Failure code [B@C7NS] (Brake oil: Overheating) ................................................................... 24 Failure code [B@CENS] (Torque converter oil: Overheating) ................................................. 26 Failure code [B@GAZK] (Battery electrolyte: Low level) ......................................................... 28 Failure code [B@HANS] (Hydraulic oil: Overheating) ............................................................. 30 Failure code [CA111] (Abnormality in engine controller) .......................................................... 32 Failure code [CA115] (Engine Ne or Bkup speed sensor error) .............................................. 34 Failure code [CA122] (Charge pressure sensor high error)..................................................... 36 Failure code [CA123] (Charge pressure sensor low error) ...................................................... 38 Failure code [CA131] (Throttle sensor high error) ................................................................... 40 Failure code [CA132] (Throttle sensor low error)..................................................................... 42 Failure code [CA135] (Engine oil pressure sensor high error)................................................. 44 Failure code [CA141] (Engine oil pressure sensor low error) .................................................. 46 Failure code [CA144] (Coolant temperature sensor high error)............................................... 48 Failure code [CA145] (Coolant temperature sensor low error) ................................................ 50 Failure code [CA153] (Charge temperature sensor high error) ............................................... 52 Failure code [CA154] (Charge temperature sensor low error)................................................. 54 Failure code [CA187] (Sensor power supply 2 low error) ........................................................ 55 Failure code [CA212] (Engine oil temperature sensor high error) ........................................... 56 Failure code [CA213] (Engine oil temperature sensor low error)............................................. 58 Failure code [CA221] (Atmospheric pressure sensor high error) ............................................ 60 Failure code [CA222] (Atmospheric pressure sensor low error) .............................................. 62 Failure code [CA227] (Sensor power supply 2 high error)....................................................... 64 Troubleshooting by failure code (Display of code), Part 3 SEN00560-00 Troubleshooting by failure code (Display of code), Part 3 ........................................................... 3 Failure code [CA234] (Engine overspeed)............................................................................... 3 Failure code [CA238] (Ne speed sensor power supply error).................................................. 4 Failure code [CA263] (Fuel temperature sensor high error) .................................................... 6 Failure code [CA265] (Fuel temperature sensor low error) ..................................................... 8 Failure code [CA271] (PCV1 Short circuit) .............................................................................. 10 Failure code [CA272] (PCV1 Disconnection)........................................................................... 12 Failure code [CA273] (PCV2 Short circuit) .............................................................................. 14 Failure code [CA274] (PCV2 Disconnection)........................................................................... 16 Failure code [CA322] (Injector #1 (L/B #1) open/short error) .................................................. 18 Failure code [CA323] (Injector #5 (L/B #5) open/short error) .................................................. 20
The KOMATSU GALEO WA600-6 WHEEL LOADER SN 60001 and up service manual is an essential resource for anyone involved in the repair and maintenance of this equipment. Whether you are a professional mechanic or a DIY enthusiast, this manual provides the necessary technical information for servicing the KOMATSU GALEO WA600-6 WHEEL LOADER SN 60001 and up.
This comprehensive manual covers all aspects of repair, including detailed substeps, notes, cautions, and warnings to ensure the correct repair procedures are followed. It also includes numbered instructions, bold figure numbers, and detailed illustrations to guide you through each repair process.
The manual is available in a file format that is compatible with all versions of Windows and Mac operating systems. It can be easily saved to your hard drive or burned to a CD-ROM for convenient access. With printable pages, there's no need to wait for shipping or deal with overpriced paper textbooks or CD-ROMs.
From safety hints to specifications, hydraulic systems, electrical systems, mechatronics systems, troubleshooting, maintenance standards, and disassembly and assembly procedures, this manual provides a comprehensive guide to maintaining and repairing the KOMATSU GALEO WA600-6 WHEEL LOADER SN 60001 and up.