KOMATSU WA500-1 SHOP MANUAL SEBM04250107 – PDF DOWNLOAD

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KOMATSU WA500-1 SHOP MANUAL SEBM04250107 – PDF DOWNLOAD

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KOMATSU WA500-1 SHOP MANUAL SEBM04250107 – PDF DOWNLOAD

Language : English
Pages : 933
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU WA500-1 SHOP MANUAL SEBM04250107 – PDF DOWNLOAD

MAIN MENU........................................................................................................................................................................................  0
CONTENTS.........................................................................................................................................................................................  3
10 ENGINE ....................................................................................................................................................................................... 41
	11 STRUCTURE AND FUNCTION ................................................................................................................................................................... 43
		ENGINE MOUNT ............................................................................................................................................................................ 44
		RADIATOR................................................................................................................................................................................. 45
		FUEL TANK AND PIPING..................................................................................................................................................................... 46
		ENGINE CONTROL........................................................................................................................................................................... 47
	12 TESTING AND ADJUSTING .................................................................................................................................................................... 49
		STANDARD VALUE TABLE..................................................................................................................................................................... 50
		TOOL LIST FOR TESTING AND ADJUSTING...................................................................................................................................................... 51
		ADJUSTING VALVE CLEARANCE................................................................................................................................................................ 52
		MEASURING COMPRESSION PRESSURE........................................................................................................................................................... 53
		TESTING AND ADJUSTING FUEL INJECTION TIMING.............................................................................................................................................. 54
		MEASURING BLOW-BY PRESSURE............................................................................................................................................................... 56
		TESTING AND ADJUSTING BELT TENSION....................................................................................................................................................... 57
		MEASURING EXHAUST GAS COLOR.............................................................................................................................................................. 58
		MEASURING ENGINE OIL PRESSURE AND TEMPERATURE............................................................................................................................................ 59
		ADJUSTING FUEL CUT SOLENOID.............................................................................................................................................................. 60
		MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE.......................................................................................................................... 61
	13 DISASSEMBLY  AND ASSEMBLY ................................................................................................................................................................ 63
		STARTING MOTOR .......................................................................................................................................................................... 64
			REMOVAL ............................................................................................................................................................................. 64
			INSTALLATION......................................................................................................................................................................... 64
		ALTERNATOR .............................................................................................................................................................................. 65
			REMOVAL.............................................................................................................................................................................. 65
			INSTALLATION......................................................................................................................................................................... 65
		OIL COOLER............................................................................................................................................................................... 66
			REMOVAL ............................................................................................................................................................................. 66
			INSTALLATION......................................................................................................................................................................... 66
		FUEL INJECTION PUMP ..................................................................................................................................................................... 67
			REMOVAL.............................................................................................................................................................................. 67
			INSTALLATION ........................................................................................................................................................................ 67
		WATER PUMP............................................................................................................................................................................... 68
			REMOVAL ............................................................................................................................................................................. 68
			INSTALLATION ........................................................................................................................................................................ 68
		NOZZLE HOLDER............................................................................................................................................................................ 69
			REMOVAL.............................................................................................................................................................................. 69
			INSTALLATION ........................................................................................................................................................................ 69
		TURBOCHARGER ............................................................................................................................................................................ 70
			REMOVAL.............................................................................................................................................................................. 70
			INSTALLATION ........................................................................................................................................................................ 70
		AIR COMPRESSOR .......................................................................................................................................................................... 71
			REMOVAL.............................................................................................................................................................................. 71
			INSTALLATION ........................................................................................................................................................................ 71
		CYLINDER HEAD............................................................................................................................................................................ 72
			REMOVAL ............................................................................................................................................................................. 72
			INSTALLATION......................................................................................................................................................................... 77
		RADIATOR ................................................................................................................................................................................ 83
			REMOVAL ............................................................................................................................................................................. 83
			INSTALLATION......................................................................................................................................................................... 85
		ENGINE .................................................................................................................................................................................. 87
			REMOVAL ............................................................................................................................................................................. 87
			INSTALLATION......................................................................................................................................................................... 93
		FUEL TANK................................................................................................................................................................................ 99
			REMOVAL.............................................................................................................................................................................. 99
			INSTALLATION.........................................................................................................................................................................100
	14 MAINTENANCE STANDARD......................................................................................................................................................................101
		ENGINE MOUNT.............................................................................................................................................................................102
20 POWER TRAIN...................................................................................................................................................................................103
	21 STRUCTURE AND FUNCTION....................................................................................................................................................................105
		GENERAL .................................................................................................................................................................................106
			HYDRAULIC CIRCUIT FOR POWER TRAIN....................................................................................................................................................108
			HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN............................................................................................................................................109
		DAMPER ..................................................................................................................................................................................112
		TORQUE CONVERTER AND TRANSMISSION PIPING ................................................................................................................................................116
		TORQUE CONVERTER CHARGING PUMP ..........................................................................................................................................................119
		TORQUE CONVERTER OIL COOLER .............................................................................................................................................................120
		TORQUE CONVERTER OIL FILTER .............................................................................................................................................................123
		TORQUE CONVERTER ........................................................................................................................................................................124
		TRANSMISSION MOUNT ......................................................................................................................................................................126
		TORQUE CONVERTER RELIEF VALVE ...........................................................................................................................................................127
		TRANSMISSION.............................................................................................................................................................................128
		TRANSMISSION CONTROL VALVE ..............................................................................................................................................................136
			UPPER VALVE..........................................................................................................................................................................138
			LOWER VALVE..........................................................................................................................................................................139
			TRANSMISSION SOLENOID VALVE..........................................................................................................................................................140
			EMERGENCY MANUAL SPOOL...............................................................................................................................................................141
			FORWARD IST..........................................................................................................................................................................142
			PRIORITY VALVE.......................................................................................................................................................................144
			MODULATING VALVE AND QUICK RETURN VALVE..............................................................................................................................................145
			ACCUMULATOR VALVE....................................................................................................................................................................148
			PILOT REDUCING VALVE.................................................................................................................................................................150
			MAIN RELIEF VALVE....................................................................................................................................................................151
			REDUCING VALVE.......................................................................................................................................................................152
			LUBRICATION BYPASS VALVE.............................................................................................................................................................153
		PILOT OIL FILTER ........................................................................................................................................................................154
		TRANSFER.................................................................................................................................................................................155
		DRIVE SHAfT .............................................................................................................................................................................156
		CENTER SUPPORT ..........................................................................................................................................................................157
		AXLE MOUNT...............................................................................................................................................................................158
		AXLE AND DIFFERENTIAL ...................................................................................................................................................................160
		FINAL DRIVE .............................................................................................................................................................................165
		TIRE AND WHEEL...........................................................................................................................................................................166
	22 TESTING AND ADJUSTING.....................................................................................................................................................................167
		STANDARD VALUE TABLE ....................................................................................................................................................................168
		TOOL LIST FOR TESTING AND ADJUSTING .....................................................................................................................................................169
		MEASURING ENGINE STALL SPEED ............................................................................................................................................................170
		MEASURING OIL PRESSURE OF TORQUE CONVERTER AND  TRANSMISSION  * .........................................................................................................................172
		MEASURING SHIFT LEVER ...................................................................................................................................................................174
		METHOD FOR OPERATION OF SPOOL EMERGENCY MANUAL  .........................................................................................................................................175
		TIRE AND WHEEL ..........................................................................................................................................................................176
		TROUBLESHOOTING..........................................................................................................................................................................177
			PRECAUTIONS WHEN TROUBLESHOOTING ....................................................................................................................................................178
			METHOD OF READING TROUBLESHOOTING TABLE .............................................................................................................................................180
			PREVENTING RECURRENCE OF TROUBLE ....................................................................................................................................................182
			METHOD OF LOCATING MAIN PROBLEM POINTS WHEN  TROUBLESHOOTING TRANSMISSION SYSTEM ....................................................................................................183
			TROUBLESHOOTING TABLE ...............................................................................................................................................................184
			1. Machine does not move.............................................................................................................................................................184
			2. Machine lacks power or speed......................................................................................................................................................186
			3. Excessive time lag when starting machine or shifting gear.........................................................................................................................187
			4. Torque converter oil temperature too high.........................................................................................................................................188
	23 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................189
		DAMPER...................................................................................................................................................................................190
			REMOVAL..............................................................................................................................................................................190
			INSTALLATION ........................................................................................................................................................................194
			DISASSEMBLY .........................................................................................................................................................................198
			ASSEMBLY ............................................................................................................................................................................200
		TORQUE CONVERTER CHARGING PUMP...........................................................................................................................................................202
			REMOVAL .............................................................................................................................................................................202
			INSTALLATION ........................................................................................................................................................................202
		TORQUE CONVERTER AND TRANSMISSION........................................................................................................................................................203
			REMOVAL .............................................................................................................................................................................203
			INSTALLATION ........................................................................................................................................................................210
		TORQUE CONVERTER.........................................................................................................................................................................217
			DISASSEMBLY .........................................................................................................................................................................217
			ASSEMBLY ............................................................................................................................................................................221
		TRANSMISSION.............................................................................................................................................................................227
			DISASSEMBLY .........................................................................................................................................................................227
			ASSEMBLY ............................................................................................................................................................................237
		TRANSFER.................................................................................................................................................................................249
			DISASSEMBLY .........................................................................................................................................................................249
			ASSEMBLY ............................................................................................................................................................................252
		TRANSMISSION CONTROL VALVE...............................................................................................................................................................256
			REMOVAL .............................................................................................................................................................................256
			INSTALLATION ........................................................................................................................................................................258
			DISASSEMBLY AND ASSEMBLY ............................................................................................................................................................260
		FRONT DIFFERENTIAL.......................................................................................................................................................................264
			REMOVAL..............................................................................................................................................................................264
			INSTALLATION.........................................................................................................................................................................267
		REAR DIFFERENTIAL........................................................................................................................................................................270
			REMOVAL..............................................................................................................................................................................270
			INSTALLATION ........................................................................................................................................................................273
		DIFFERENTIAL GEAR........................................................................................................................................................................276
			DISASSEMBLY .........................................................................................................................................................................276
			ASSEMBLY ............................................................................................................................................................................280
		FRONT AXLE...............................................................................................................................................................................286
			REMOVAL..............................................................................................................................................................................286
			INSTALLATION.........................................................................................................................................................................288
		REAR AXLE................................................................................................................................................................................290
			REMOVAL..............................................................................................................................................................................290
			INSTALLATION.........................................................................................................................................................................294
		CENTER SUPPORT...........................................................................................................................................................................298
			REMOVAL .............................................................................................................................................................................298
			INSTALLATION ........................................................................................................................................................................299
			DISASSEMBLY..........................................................................................................................................................................300
			ASSEMBLY ............................................................................................................................................................................302
		DRIVE SHAFT Serial No. 10001 - 10222.....................................................................................................................................................304
			DISASSEMBLY .........................................................................................................................................................................304
			ASSEMBLY ............................................................................................................................................................................306
		DRIVE SHAFT Serial No. 10223 and up......................................................................................................................................................308
			DISASSEMBLY .........................................................................................................................................................................308
			ASSEMBLY.............................................................................................................................................................................310
		FINAL DRIVE..............................................................................................................................................................................312
			DISASSEMBLY..........................................................................................................................................................................312
			ASSEMBLY ............................................................................................................................................................................315
	24 MAINTENANCE  STANDARD ....................................................................................................................................................................319
		TRANSMISSION MOUNT.......................................................................................................................................................................320
		TORQUE CONVERTER CHARGING PUMP ..........................................................................................................................................................321
		DAMPER...................................................................................................................................................................................322
		TORQUE CONVERTER ........................................................................................................................................................................325
		TRANSMISSION.............................................................................................................................................................................326
		TRANSFER ................................................................................................................................................................................334
		DRIVE SHAFT..............................................................................................................................................................................336
		CENTER SUPPORT ..........................................................................................................................................................................337
		DIFFERENTIAL.............................................................................................................................................................................338
		AXLE MOUNT...............................................................................................................................................................................342
		FINAL DRIVE .............................................................................................................................................................................344
40 STEERING SYSTEM...............................................................................................................................................................................345
	41 STRUCTURE AND FUNCTION ...................................................................................................................................................................347
		GENERAL .................................................................................................................................................................................348
		HYDRAULIC CIRCUIT FOR STEERING ..........................................................................................................................................................350
			HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...............................................................................................................................................351
			OPERATIONS OF STEERING VALVE ........................................................................................................................................................352
		STEERING CONTROL SYSTEM .................................................................................................................................................................354
			STEERING VALVE.......................................................................................................................................................................354
			STEERING RELIEF VALVE................................................................................................................................................................356
			SAFETY VALVE (with suction valve)....................................................................................................................................................357
			OPERATION OF DEMAND SPOOL............................................................................................................................................................358
			TWO-WAY RESTRICTOR VALVE.............................................................................................................................................................361
			ROTOR SEAL...........................................................................................................................................................................362
		STEERING CYLINDER........................................................................................................................................................................363
		STEERING COLUMN AND GEAR BOX ............................................................................................................................................................364
		STEERING LINKAGE ........................................................................................................................................................................365
		STEERING PUMP ...........................................................................................................................................................................366
		CENTER HINGE PIN.........................................................................................................................................................................367
	42 TESTING  AND ADJUSTING ...................................................................................................................................................................369
		STANDARD VALUE TABLE ....................................................................................................................................................................370
		TOOL LIST FOR TESTING AND ADJUSTING .....................................................................................................................................................370
		MEASURING STEERING WHEEL PLAY ...........................................................................................................................................................371
		MEASURING OPERATING FORCE OF STEERING WHEEL .............................................................................................................................................372
		OPERATING TIME OF STEERING WHEEL ........................................................................................................................................................373
		TESTING STEERING LINKAGE ................................................................................................................................................................374
		ADJUSTING STEERING LINKAGE ..............................................................................................................................................................375
		STEERING OIL PRESSURE ...................................................................................................................................................................376
		TROUBLESHOOTING..........................................................................................................................................................................377
			TROUBLESHOOTING TABLE ...............................................................................................................................................................378
			1. Steering wheel does not turn......................................................................................................................................................378
			2. Steering wheel is sluggish........................................................................................................................................................379
			3. Steering wheel moves unsteadily or is subjected to large shock....................................................................................................................380
			4. Machine tends to turn naturally in one particular direction when traveling........................................................................................................380
			5. Left and right turning radii are different........................................................................................................................................380
	42 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................381
		STEERING GEAR BOX........................................................................................................................................................................382
			REMOVAL .............................................................................................................................................................................382
			INSTALLATION ........................................................................................................................................................................383
			DISASSEMBLY .........................................................................................................................................................................384
			ASSEMBLY ............................................................................................................................................................................385
		STEERING VALVE...........................................................................................................................................................................387
			REMOVAL .............................................................................................................................................................................387
			INSTALLATION ........................................................................................................................................................................389
			DISASSEMBLY AND ASSEMBLY ............................................................................................................................................................391
		STEERING PUMP AND POC PUMP...............................................................................................................................................................393
			REMOVAL .............................................................................................................................................................................393
			INSTALLATION ........................................................................................................................................................................394
		STEERING CYLINDER........................................................................................................................................................................395
			REMOVAL .............................................................................................................................................................................395
			INSTALLATION ........................................................................................................................................................................396
			DISASSEMBLY .........................................................................................................................................................................397
			ASSEMBLY ............................................................................................................................................................................399
		CENTER HINGE PIN.........................................................................................................................................................................402
			REMOVAL .............................................................................................................................................................................402
			INSTALLATION ........................................................................................................................................................................408
	44 MAINTENANCE STANDARD......................................................................................................................................................................415
		STEERING LINKAGE ........................................................................................................................................................................416
		STEERING COLUMN AND GEAR BOX ............................................................................................................................................................417
		STEERING PUMP ...........................................................................................................................................................................418
		STEERING VALVE ..........................................................................................................................................................................419
		STEERING CYLINDER MOUNT .................................................................................................................................................................420
		STEERING CYLINDER .......................................................................................................................................................................421
		CENTER HINGE PIN ........................................................................................................................................................................422
50 BRAKE AND AIR SYSTEM..........................................................................................................................................................................425
	51 STRUCTURE AND FUNCTION....................................................................................................................................................................427
		GENERAL .................................................................................................................................................................................428
		AIR TANK ................................................................................................................................................................................431
		SAFETY VALVE ............................................................................................................................................................................431
		BRAKE VALVE .............................................................................................................................................................................432
			BRAKE ACTUATED.......................................................................................................................................................................433
			OPERATING IN BALANCE.................................................................................................................................................................434
			BRAKE RELEASED.......................................................................................................................................................................435
		AIR GOVERNOR ............................................................................................................................................................................436
		TWO-WAY VALVE ...........................................................................................................................................................................438
		BRAKE CHAMBER ...........................................................................................................................................................................439
		SLACK ADJUSTER ..........................................................................................................................................................................441
		BRAKE ...................................................................................................................................................................................444
		PARKING BRAKE ...........................................................................................................................................................................446
		PARKING BRAKE SOLENOID VALVE ............................................................................................................................................................448
		SPRING CYLINDER .........................................................................................................................................................................451
		BRAKE CALIPER ...........................................................................................................................................................................452
	52 TESTING AND ADJUSTING.....................................................................................................................................................................453
		STANDARD VALUE TABLE ....................................................................................................................................................................454
		TOOL LIST FOR TESTING AND ADJUSTING .....................................................................................................................................................455
		MEASURING BRAKE PEDAL ...................................................................................................................................................................456
		MEASURING AIR ...........................................................................................................................................................................457
		BRAKE PERFORMANCE .......................................................................................................................................................................460
		CHECKING BRAKE PISTON LEAKAGE ...........................................................................................................................................................461
		MEASURING WEAR OF BRAKE DISC ............................................................................................................................................................462
		AIR BLEEDING FROM BRAKE LINE ............................................................................................................................................................463
		PARKING BRAKE PERFORMANCE ...............................................................................................................................................................464
		CHECKING AND ADJUSTING PARKING BRAKE ....................................................................................................................................................465
		TROUBLESHOOTING..........................................................................................................................................................................467
			TROUBLESHOOTING TABLE ...............................................................................................................................................................468
			1. Air pressure does not rise at all.................................................................................................................................................468
			2. Air pressure does not rise to the specified range.................................................................................................................................469
			3. Brake is ineffective or not very effective........................................................................................................................................470
			4. Brake does not release, or drags..................................................................................................................................................471
			5. Parking brake does not release, or drags.  (Applies to machine equiped with air parking brake.)...................................................................................472
	53 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................473
		AIR GOVERNOR.............................................................................................................................................................................474
			DISASSEMBLY .........................................................................................................................................................................474
			ASSEMBLY ............................................................................................................................................................................475
		BRAKE VALVE..............................................................................................................................................................................476
			REMOVAL .............................................................................................................................................................................476
			INSTALLATION.........................................................................................................................................................................477
			DISASSEMBLY .........................................................................................................................................................................478
			ASSEMBLY ............................................................................................................................................................................480
		BRAKE CHAMBER............................................................................................................................................................................482
			REMOVAL .............................................................................................................................................................................482
			INSTALLATION ........................................................................................................................................................................484
			DISASSEMBLY .........................................................................................................................................................................486
			ASSEMBLY ............................................................................................................................................................................489
		SLACK ADJUSTER...........................................................................................................................................................................492
			REMOVAL .............................................................................................................................................................................492
			INSTALLATION.........................................................................................................................................................................492
			DISASSEMBLY .........................................................................................................................................................................493
			ASSEMBLY ............................................................................................................................................................................494
		BRAKE....................................................................................................................................................................................495
			REMOVAL .............................................................................................................................................................................495
			INSTALLATION ........................................................................................................................................................................497
			DISASSEMBLY .........................................................................................................................................................................500
			ASSEMBLY ............................................................................................................................................................................504
		SPRING CYLINDER..........................................................................................................................................................................508
			REMOVAL .............................................................................................................................................................................508
			INSTALLATION ........................................................................................................................................................................509
			DISASSMBLY...........................................................................................................................................................................510
			ASSEMBLY.............................................................................................................................................................................510
		PARKING BRAKE............................................................................................................................................................................511
			REMOVAL .............................................................................................................................................................................511
			INSTALLATION ........................................................................................................................................................................514
		PARKING BRAKE PAD........................................................................................................................................................................517
			REMOVAL..............................................................................................................................................................................517
			INSTALLATION.........................................................................................................................................................................517
	54 MAINTENANCE STANDARD......................................................................................................................................................................519
		BRAKE VALVE .............................................................................................................................................................................520
		BRAKE CHAMBER ...........................................................................................................................................................................522
		SLACK ADJUSTER ..........................................................................................................................................................................523
		BRAKE ...................................................................................................................................................................................524
		PARKING BRAKE ...........................................................................................................................................................................526
		SPRING CYLINDER .........................................................................................................................................................................527
60 WORK EQUIPMENT SYSTEM.........................................................................................................................................................................529
	61 STRUCTURE AND FUNCTION....................................................................................................................................................................531
		GENERAL .................................................................................................................................................................................532
		HYDRAULIC CIRCUIT SYSTEM ................................................................................................................................................................534
		HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................................535
		WORK EQUIPMENT LEVER LINKAGE ............................................................................................................................................................536
		HYDRAULK TANK............................................................................................................................................................................538
			OIL FILTER BYPASS VALVE..............................................................................................................................................................539
			BREATHER.............................................................................................................................................................................539
		HYDRAULIC PUMPS..........................................................................................................................................................................540
			HYDRAULtC PUMP.......................................................................................................................................................................540
			SWtTCH PUMP..........................................................................................................................................................................540
			POC PUMP.............................................................................................................................................................................541
		POC VALVE ...............................................................................................................................................................................542
		MAIN CONTROL VALVE ......................................................................................................................................................................550
			RELIEF VALVE.........................................................................................................................................................................552
			SAFETY VALVE.........................................................................................................................................................................553
			SUCTION VALVE........................................................................................................................................................................554
			FLOAT SELECTOR VALVE AND UNLOADER VALVE..............................................................................................................................................555
		HYDRAULIC CYLINDER ......................................................................................................................................................................562
		BUCKET POSITIONER AND BOOM KICK-OUT .....................................................................................................................................................564
		BUCKET LINKAGE ..........................................................................................................................................................................566
		BUCKET ..................................................................................................................................................................................568
		ACCUMULATOR .............................................................................................................................................................................569
	62 TESTING AND ADJUSTING.....................................................................................................................................................................571
		STANDARD VALUE TABLE.....................................................................................................................................................................572
		TOOL LIST FOR TESTING AND ADJUSTING .....................................................................................................................................................575
		MEASURING DUMP AND LIFT  CONTROL LEVERS .................................................................................................................................................576
		ADJUSTING  DUMP AND LIFT CONTROL LEVERS .................................................................................................................................................577
		MEASURING HYDRAULIC  PRESSURE OF WORK’EQUIPME,NT ........................................................................................................................................578
		MEASURING WORK EQUIPMENT ................................................................................................................................................................581
		MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT .............................................................................................................................................582
		ADJUSTING BUCKET POSITIONER .............................................................................................................................................................583
		ADJUSTING BOOM KICK-OUT .................................................................................................................................................................584
		TROUBLESHOOTING..........................................................................................................................................................................585
			TROUBLESHOOTING TABLE ...............................................................................................................................................................586
			1. Lift arm does not rise............................................................................................................................................................586
			*** MISSING 2-7 (PGS 62-15 THROUGH 62-22)............................................................................................................................................555
			8. Bucket does not tilt back.........................................................................................................................................................587
			9. Bucket moves slowly or has insufficient tilt back power...........................................................................................................................588
			10. Bucket movement becomes slow during tilt back....................................................................................................................................589
			11. Bucket cannot be held down by the bucket cylinder................................................................................................................................589
			12. Bucket has large hydraulic drift.................................................................................................................................................589
			13. Bucket moves unsteadily when machine travels under load.  (Main control valve in "Hold").........................................................................................589
			14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back". ..............................................................................................589
			15. Control levers of lift arm and dump move stiffly and sluggishly..................................................................................................................590
	63 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................591
		HYDRAULIC TANK...........................................................................................................................................................................592
			REMOVAL .............................................................................................................................................................................592
			INSTALLATION ........................................................................................................................................................................593
		HYDRAULIC PUMP...........................................................................................................................................................................594
			REMOVAL .............................................................................................................................................................................594
			INSTALLATION ........................................................................................................................................................................594
		HYDRAULIC FILTER.........................................................................................................................................................................595
			REMOVAL .............................................................................................................................................................................595
			INSTALLATION.........................................................................................................................................................................595
		SWITCH PUMP..............................................................................................................................................................................596
			REMOVAL..............................................................................................................................................................................596
			INSTALLATION ........................................................................................................................................................................597
		POC VALVE................................................................................................................................................................................598
			REMOVAL .............................................................................................................................................................................598
			INSTALLATION ........................................................................................................................................................................600
			DISASSEMBLY .........................................................................................................................................................................602
			ASSEMBLY ............................................................................................................................................................................602
		MAIN CONTROL VALVE.......................................................................................................................................................................603
			REMOVAL .............................................................................................................................................................................603
			INSTALLATION ........................................................................................................................................................................605
			DISASSEMBLY AND ASSEMBLY ............................................................................................................................................................608
		DUMP CYLINDER............................................................................................................................................................................610
			REMOVAL .............................................................................................................................................................................610
			INSTALLATION.........................................................................................................................................................................612
		LIFT CYLINDER............................................................................................................................................................................614
			REMOVAL .............................................................................................................................................................................614
			INSTALLATION ........................................................................................................................................................................615
		LIFT AND DUMP CYLINDERS..................................................................................................................................................................617
			DISASSEMBLY .........................................................................................................................................................................617
			ASSEMBLY ............................................................................................................................................................................619
		WORK EQUIPMENT...........................................................................................................................................................................622
			REMOVAL..............................................................................................................................................................................622
			INSTALLATION.........................................................................................................................................................................626
		COUNTERWEIGHT............................................................................................................................................................................633
			REMOVAL..............................................................................................................................................................................633
			INSTALLATION.........................................................................................................................................................................633
	64 MAINTENANCE STANDARD .....................................................................................................................................................................635
		MAIN CONTROL VALVE ......................................................................................................................................................................636
		DUMP CYLINDER ...........................................................................................................................................................................638
		LIFT CYLINDER ...........................................................................................................................................................................639
		BUCKET LINKAGE...........................................................................................................................................................................640
		BUCKET POSITIONER AND BOOM KICK-OUT .....................................................................................................................................................642
		BUCKET ..................................................................................................................................................................................643
		HYDRAULIC AND SWlTCH PUMP ...............................................................................................................................................................644
		POC PUMP ................................................................................................................................................................................645
		POC VALVE ...............................................................................................................................................................................646
80 ELECTRIC AND ELECTRONIC SYSTEM ...............................................................................................................................................................647
	81 STRUCTURE AND FUNCTION....................................................................................................................................................................647
		ELECTRIC AND ELECTRONIC SYSTEM...........................................................................................................................................................  0
		ELECTRICAL WIRING DIAGRAM CIRCUIT........................................................................................................................................................648
		ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER .......................................................................................................................................653
		ENGINE STARTING CIRCUIT .................................................................................................................................................................654
		ENGINE STOP CIRCUIT .....................................................................................................................................................................657
		PREHEATING CIRCUIT.......................................................................................................................................................................659
			PREHEATING WITH STARTING SWITCH......................................................................................................................................................659
			AUTOMATIC PREHEATING.................................................................................................................................................................660
		COMBINATION SWITCH.......................................................................................................................................................................661
		ELECTRICAL TRANSMISSION CONTROL .........................................................................................................................................................662
			TRANSMISSION CUT-OFF SWITCH..........................................................................................................................................................663
			TRANSMISSION CUT-OFF SELECTOR SWITCH.................................................................................................................................................664
			NEUTRALIZER RELAY....................................................................................................................................................................665
		ELECTRICAL PARKING BRAKE CONTROL ........................................................................................................................................................666
		ELECTRONIC VEHICLE MONITORING SYSTEM  (EVMS).............................................................................................................................................675
			MONITOR PANEL........................................................................................................................................................................675
			INDICATION ON MONITOR PANEL..........................................................................................................................................................679
			CONTROLLER...........................................................................................................................................................................681
			WIRING HARNESS.......................................................................................................................................................................682
			SENSORS .............................................................................................................................................................................684
			CONTACT SWITCH.......................................................................................................................................................................689
		OPERATION OF CONTACT SWITCH .............................................................................................................................................................690
	82 TESTING AND ADJUSTING.....................................................................................................................................................................695
		STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ..............................................................................................................................................696
		ADJUSTING SPEEDOMETER MODULE OF MACHINE  MONITOR ........................................................................................................................................699
		CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR ...........................................................................................................................................701
		TROUBLESHOOTING..........................................................................................................................................................................703
			CHECK BEFORE TROUBLESHOOTING ........................................................................................................................................................704
			METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART ...................................................................................................................................705
			CONNECTOR TERMINAL NUMBERS ..........................................................................................................................................................707
			PRECAUTION WHEN HANDLING CONNECTOR ..................................................................................................................................................711
			ELECTRICAL WIRING DIAGRAM............................................................................................................................................................713
			ELETRICAL CIRCUIT SYSTEM.............................................................................................................................................................714
			TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-15)..............................................................................................................................723
				E-1 ENGINE DOES NOT START........................................................................................................................................................724
				E-1A ENGINE DOES NOT START (STARTING MOTOR ROTATES)..............................................................................................................................726
				E-2 ENGINE DOES NOT STOP.........................................................................................................................................................729
				E-3 ENGINE STOPS WHEN TRAVELING..................................................................................................................................................730
				E-4 a)PARKING BRAKE DOES NOT WORK (PARKING BRAKE SWITCH ON)......................................................................................................................732
					b)PARKlNG BRAKE DOES NOT WORK. (AIR PRESSURE LESS THAN 2.0kg/cm2)............................................................................................................732
				E-5 PARKING BRAKE IS NOT RELEASED................................................................................................................................................736
				E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON...............................................................................................................740
				E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED........................................................................................................740
				E-8 MACHINE DOES NOT TRAVEL FORWARD..............................................................................................................................................744
				E-9 MACHINE DOES NOT TRAVEL REVERSE..............................................................................................................................................748
				E-10 TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL).....................................................................................................................752
				E-11 MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF SWITCH IS ON......................................................................................................................754
				E-12 TRANSMISSION CANNOT BE CUT-OFF..............................................................................................................................................755
				E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL ....................................................................................................................................756
				E-14 PREHEATING DISPLAY DOES NOT GO OUT..........................................................................................................................................758
				E-15 PREHATING DOES NOT WORK.....................................................................................................................................................759
			TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 to M-11)(Serial No. 10001-10662).................................................................................760
				M-1 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE STARTING ITEM..................................................764
					a) BRAKE OIL LEVEL FLASHES...................................................................................................................................................764
					b) ENGINE OIL LEVEL FLASHES..................................................................................................................................................765
					c) COOLANT LEVEL FLASHES.....................................................................................................................................................766
				M-2 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM FLASHES........................................................767
					a) BATTERY CHARGE FLASHES....................................................................................................................................................767
					b) FUEL LEVEL FLASHES........................................................................................................................................................768
					c) CLOGGING IN TRANsMlSSl0N OIL FILTER FLASHES...............................................................................................................................769
				M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND  THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS  FLASHES........................................................770
					a) FAILURE IN BRAKE LINE FLASHES.............................................................................................................................................770
					b) ENGINE OIL PRESSURE FLASHES...............................................................................................................................................771
					c) COOLANT LEVEL FLASHES.....................................................................................................................................................772
					d) DROP IN AIR PRESSURE FLASHES..............................................................................................................................................773
					e) COOLANT TEMPERATURE FLASHES ..............................................................................................................................................774
					f) TORQUE CONVERTER OIL TEMPERATURE FLASHES. ................................................................................................................................775
				M-4 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, PILOT ITEM LIGHTS UP ABNORM.................................................776
					a) PARKING BRAKE DISPLAY DOES NOT GO OUT.....................................................................................................................................776
					b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP...................................................................................................................................777
					c) WORKING LAMP DISPLAY DOES NOT GO OUT......................................................................................................................................778
					d) WORKING LAMP DISPLAY DOES NOT LIGHT UP....................................................................................................................................779
					e) PREHEAT DISPLAY LIGHTS UP.................................................................................................................................................780
					f) PREHEAT DISPLAY DOES NOT LIGHT UP.........................................................................................................................................781
					g) FAILURE IN MAIN STEERING DISPLAY LIGHTS UP (IF EQUIPPED)..................................................................................................................782
					h) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)..........................................................................................................783
					i) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED).................................................................................................................784
					i) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED).........................................................................................................785
					k) TRANSMISSION CUT-OFF DISPLAY LIGHTS UP....................................................................................................................................786
					I) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP............................................................................................................................787
				M-5 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY,  OR DO NOT LIGHT UP. ......................................................................................................788
					a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP.......................................................................................................................788
					b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP........................................................................................................................788
					c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP...............................................................................................................789
					d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP................................................................................................................790
					e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP....................................................................................................................................791
					f) HIGH BEAM PILOT LAMP DOES NOT GO OUT......................................................................................................................................792
				M-6 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...................................................................................................................................793
				M-7 SERVICE METER DOES NOT WORK NORMALLY.........................................................................................................................................794
				M-8 ABNORMALITY IN MONITOR PANEL.................................................................................................................................................796
					a) NONE OF MONITOR PANEL WORKS...............................................................................................................................................796
					*** MISSING "b)..." (PG 82-79 & 82-80).......................................................................................................................................796
					c) EVEN WHEN ENGINE IS STOPPED (ENGINE OIL PRESSURE) FLASHES, CAUTION BUZZER SOUNDS AND WARNING .............................................................................797
					d) EVEN WHEN ENGINE STOPPED, I- (BATTERY CHARGE)  L-J  FLASHES AND WARNING LAMP LIGHTS UP. ..................................................................................798
					e) NO LAMPS ON MONITOR LIGHTS UP (IMMEDIATELY AFTER TURNING STARGING  SWITCH TO  “ON”, ENGINE STOPPED.) .....................................................................798
					f) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING  LAMP LIGHTS UP INTERMITTENTLY.......................................................................................799
					g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY...............................................................................................................................800
					h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY.........................................................................................801
					i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY................................................................................................................................802
				M-9 ABNORMALITY IN PANEL LAMPS ON MONITOR .......................................................................................................................................804
					a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED.............................................................................................804
					b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS .............................................................................................................................806
					c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP...............................................................................................................................807
					d) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP................................................................................................808
					e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP..............................................................................................................................809
				M-10 ABNORMALITY IN ALARM BUZZER OR WARNING LAMP. ...............................................................................................................................810
					a) EMERGENCY ITEMS IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND..............................................................................................................810
					b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH.........................................................................................812
				M-11 ABNORMALITY IN GAUGE. ......................................................................................................................................................814
					a) FUEL GAUGE   .............................................................................................................................................................814
					b) AIR PRESSURE GUAGE........................................................................................................................................................816
					c) COOLANT TEMPERATURE GAUGE.................................................................................................................................................818
					d) TORQUE CONVERTER OIL TEMPERATURE GAUGE....................................................................................................................................820
			TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (Electronic vehicle monitoring system)(Serial No. 10663 and UP).......................................................823
				CONNECTOR TYPES AND LOCATION OF COMPONENTS ......................................................................................................................................825
				M-1 BRAKE OIL LEVEL FLASHES WHEN ENGINE  IS STOPPED. ............................................................................................................................838
				M-2 ENGINE OIL LEVEL FLASHES WHEN ENGINE IS STOPPED..............................................................................................................................838
				M-3 RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS STOPPED..........................................................................................................................840
				M-4 BATTERY CHARGE FLASHES WHEN ENGINE IS RUNNING................................................................................................................................840
				M-5 TRANSMISSION OIL FILTER CLOGGING FLASHES WHEN ENGINE IS RUNNING. ............................................................................................................842
				M-6 FUEL LEVEL FLASHES WHEN ENGINE IS RUNNING....................................................................................................................................844
				M-7 BRAKE LINE FAILURE FLASHES WHEN ENGINE IS RUNNING. ..........................................................................................................................844
				M-8 ENGINE OIL PRESSURE FLASHES WHEN ENGINE IS RUNNING...........................................................................................................................846
				M-9 RADIATOR WATER LEVEL FLASHES WHEN  ENGINE IS RUNNING.........................................................................................................................846
				M-10 DROP IN AIR PRESSURE FLASHES WHEN ENGINE IS RUNNING.........................................................................................................................848
				M-11 ENGINE WATER TEMPERATURE FLASHES WHEN ENGINE IS RUNNING.....................................................................................................................848
				M-12 TORQUE CONVERTER OIL TEMPERATURE FLASHES WHEN ENGINE IS RUNNING.............................................................................................................848
				M-13 PARKING BRAKE LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP....................................................................................................................850
					a) If parking brake stays lighted up ........................................................................................................................................852
					b) If parking brake does not light up .......................................................................................................................................852
				M-14 WORKING LAMP LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.....................................................................................................................852
					a) if working lamp stays lighted up..........................................................................................................................................852
					b) If working lamp does not light up.........................................................................................................................................852
				M-15 PREHEATING LIGHTS UP, OR DOES NOT LIGHT UP..................................................................................................................................854
					a) Preheating lights up......................................................................................................................................................854
					b) Preheating does not light up..............................................................................................................................................854
				M-16 TRANSMISSION CUT-OFF LIGHTS UP, DOES NOT LIGHT UP...........................................................................................................................856
					a) Transmission cut-off lights up............................................................................................................................................856
					b) Transmission cut-off does not light up....................................................................................................................................856
				M-17 TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP............................................................................................................................858
					a) Turn signal (right) pilot display lights up...............................................................................................................................858
					b) Turn signal (left) pilot display lights up................................................................................................................................859
					c) Turn signal (right) pilot display does not light up.......................................................................................................................860
					d) Turn signal (left) pilot display does not light up........................................................................................................................860
					e) Hi beam pilot does not light up...........................................................................................................................................861
					f) Hi beam pilot stays lighted up............................................................................................................................................861
				M-18 TURN SIGNAL DOES NOT FLASH EVEN WHEN  HAZARD SWITCH IS TURNED ON............................................................................................................863
				M-19 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY. ................................................................................................................................864
				M-20 HOURMETER DOES NOT WORK NORMALLY. ..........................................................................................................................................865
				M-21 WHEN STARTING SWITCH IS TURNED ON,  MONITOR PANEL DOES NOT WORK,  OR ONLY PART WORKS. ......................................................................................866
					a) None of monitor panel lights up...........................................................................................................................................866
					b) Except for speedometer module, none of monitor panel lights up............................................................................................................866
					c) None of CAUTION items light up ...........................................................................................................................................867
					d) Some other parts do not light up .........................................................................................................................................867
				M-22  WHEN STARTING SWITCH IS TURNED ON,  ALL MONITOR PANEL LIGHTS UP,  BUT DOES NOT GO OUT. ....................................................................................867
				M-23 (ENGINE OIL PRESSURE) FLASHES OR (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED. ..........................................................................................868
					a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated.............................................................................................868
					b) (Battery charge) flashes, and warning lamp lights up......................................................................................................................868
				M-24 NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP. ...............................................................................................870
					a) Even when combination lamp is placed at SMALL, none of panel lighting lights up...........................................................................................870
					b) Even when working lamp is switched ON, none of monitor  panel lights up ..................................................................................................872
					c) Even when starting switch is turned ON, none of monitor  panel lights up .................................................................................................874
					d) Part of panel does not light up ..........................................................................................................................................874
				M-25 WHEN STARTING SWITCH IS TURNED TO ON  POSITION (ENGINE STOPPED),  BUZZER DOES NOT SOUND FOR 1 SEC.  CAUTION ITEM IS FLASHING BUT BUZZER  DOES NOT SOUND. ...................876
				M-26 NO ABNORMALITY IS SHOWN ON MONITOR  DISPLAY, BUT ALARM BUZZER SOUNDS. ......................................................................................................876
				M-27 WHEN STARTING SWITCH IS TURNED TO ON  POSITION (ENGINE STOPPED),  WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC.  CAUTION ITEM IS FLASHING BUT WARNING LAMP  DOES NOT FLASH. ....878
				M-28 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNIGN LAMP LIGHTS UP......................................................................................................879
				M-29 ABNORMALITY IN (FUEL GAUGE) SYSTEM   .......................................................................................................................................880
					a) If nothing is displayed in display area ..................................................................................................................................880
					b) If indicator remains at FULL .............................................................................................................................................880
				M-30 ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM .................................................................................................................................882
					a) If nothing is displayed in display area ..................................................................................................................................882
					b) If indicator remains at maximum level ....................................................................................................................................882
				M-31 ABNORMALITY IN ENGINE WATER TEMPERRATURE GUAGE SYSTEM.......................................................................................................................884
					a) If nothing is displayed in display area...................................................................................................................................884
					b) If indicator remains at minimum level.....................................................................................................................................884
				M-32 ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM .............................................................................................................886
					a) If nothing is displayed in display area ..................................................................................................................................886
					b) If indicator remains at minimum level ....................................................................................................................................886
	83 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................889
		MONITOR MACHINE .........................................................................................................................................................................890
			Serial No. 10001-10662...............................................................................................................................................................890
				REMOVAL..........................................................................................................................................................................890
				INSTALLATION.....................................................................................................................................................................890
			Serial No. 10663 and up..............................................................................................................................................................891
				REMOVAL..........................................................................................................................................................................891
				INSTALLATION.....................................................................................................................................................................892
90 OTHERS........................................................................................................................................................................................893
	91 OTHERS....................................................................................................................................................................................893
		CAB......................................................................................................................................................................................894
		AIR CONDITIONER..........................................................................................................................................................................895
			PIPING...............................................................................................................................................................................895
			AIR CONDITIONER WIRING DIAGRAM.......................................................................................................................................................896
			AIR CONDITIONER ELECTRIC CIRCUIT.....................................................................................................................................................897
			AIR CONDITIONER UNIT.................................................................................................................................................................898
			COMPRESSOR...........................................................................................................................................................................900
			CONDENSER............................................................................................................................................................................901
			DRY RESERVOIR........................................................................................................................................................................902
	93 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................903
		CAB......................................................................................................................................................................................904
			REMOVAL..............................................................................................................................................................................904
			INSTALLATION.........................................................................................................................................................................905
		AIR CONDITIONER UNIT (If equipped).......................................................................................................................................................906
			REMOVAL..............................................................................................................................................................................906
			INSTALLATION.........................................................................................................................................................................908
		AIR CONDITIONER CONDENSER................................................................................................................................................................910
			REMOVAL..............................................................................................................................................................................910
			INSTALLATION.........................................................................................................................................................................910
		DRY RESERVOIR............................................................................................................................................................................911
			REMOVAL..............................................................................................................................................................................911
			INSTALLATION.........................................................................................................................................................................911
		COMPRESSOR FOR AIR CONDITIONER...........................................................................................................................................................912
			(For DAIKIN air conditioner).........................................................................................................................................................912
				REMOVAL..........................................................................................................................................................................912
				INSTALLATION.....................................................................................................................................................................912
			(For DENS0 air conditioner)..........................................................................................................................................................913
				REMOVAL..........................................................................................................................................................................913
				INSTALLATION.....................................................................................................................................................................914
	97 GEAR PUMP SA SERIES.......................................................................................................................................................................915
		STRUCTURE................................................................................................................................................................................916
		TESTING AND ADJUSTING....................................................................................................................................................................919
		DISASSEMBLY..............................................................................................................................................................................922
		ASSEMBLY.................................................................................................................................................................................926
		MAINTENANCE STANDARD.....................................................................................................................................................................931

DESCRIPTION:

KOMATSU WA500-1 SHOP MANUAL SEBM04250107 – PDF DOWNLOAD

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

S.S 29/12/24