KOMATSU WA500-1 SHOP MANUAL SEBM0425M102 – PDF DOWNLOAD

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KOMATSU WA500-1 SHOP MANUAL SEBM0425M102 – PDF DOWNLOAD

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KOMATSU WA500-1 SHOP MANUAL SEBM0425M102 – PDF DOWNLOAD

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Pages : 792
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KOMATSU WA500-1 SHOP MANUAL SEBM0425M102 – PDF DOWNLOAD

COVER..................................................................................................................................................................................  1
CONTENTS...............................................................................................................................................................................  2
10 STRUCTURE AND FUNCTION.............................................................................................................................................................. 17
	GENERAL............................................................................................................................................................................ 18
	RADIATOR AND OIL COOLER............................................................................................................................................................ 20
	DAMPER............................................................................................................................................................................. 22
	TORQUE CONVERTER AND TRANSMISSION PIPING........................................................................................................................................... 24
	HYDRAULIC CIRCUIT FOR POWER TRAIN.................................................................................................................................................. 26
	HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.......................................................................................................................................... 27
	TORQUE CONVERTER AND PTO........................................................................................................................................................... 30
	TRANSMISSION....................................................................................................................................................................... 32
	TRANSMISSION CONTROL VALVE......................................................................................................................................................... 37
	TRANSMISSION SOLENOID VALVE........................................................................................................................................................ 40
	TORQUE CONVERTER OIL FILTER........................................................................................................................................................ 56
	PILOT OIL FILTER................................................................................................................................................................... 57
	TRANSFER........................................................................................................................................................................... 58
	DRIVE SHAFT........................................................................................................................................................................ 59
	CENTER SUPPORT..................................................................................................................................................................... 60
	AXLE .............................................................................................................................................................................. 61
	DIFFERENTIAL....................................................................................................................................................................... 63
	FINAL DRIVE........................................................................................................................................................................ 66
	AXLE MOUNT......................................................................................................................................................................... 68
	TIRE AND WHEEL..................................................................................................................................................................... 70
	CENTER HINGE PIN................................................................................................................................................................... 71
	STEERING PIPING.................................................................................................................................................................... 72
	STEERING CIRCUIT DIAGRAM........................................................................................................................................................... 73
	STEERING COLUMN AND GEAR BOX....................................................................................................................................................... 74
	STEERING LINKAGE................................................................................................................................................................... 75
	STEERING VALVE..................................................................................................................................................................... 76
	BRAKE AND AIR PIPING............................................................................................................................................................... 89
	BRAKE AND AIR CIRCUIT DIAGRAM...................................................................................................................................................... 91
	BRAKE AND AIR CIRCUIT SYSTEM....................................................................................................................................................... 92
	AIR GOVERNOR....................................................................................................................................................................... 93
	AIR TANK........................................................................................................................................................................... 95
	SAFETY VALVE....................................................................................................................................................................... 96
	BRAKE VALVE........................................................................................................................................................................ 97
	TWO-WAY VALVE......................................................................................................................................................................101
	BRAKE CHAMBER......................................................................................................................................................................102
	SLACK ADJUSTER.....................................................................................................................................................................104
	CHECK VALVE........................................................................................................................................................................107
	PARKING BRAKE SOLENOID VALVE.......................................................................................................................................................108
	SPRING CYLINDER....................................................................................................................................................................110
	BRAKE .............................................................................................................................................................................111
	PARKING BRAKE......................................................................................................................................................................113
	BRAKE CALIPER......................................................................................................................................................................114
	HYDRAULIC PIPING...................................................................................................................................................................115
	HYDRAULIC CIRCUIT SYSTEM...........................................................................................................................................................117
	HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................................................118
	WORK EQUIPMENT LEVER LINKAGE.......................................................................................................................................................119
	HYDRAULIC TANK.....................................................................................................................................................................120
	ACCUMULATOR........................................................................................................................................................................123
	PPC VALVE..........................................................................................................................................................................124
	PPC RELIEF VALVE...................................................................................................................................................................130
	MAIN CONTROL VALVE.................................................................................................................................................................131
	OPERATION OF MAIN CONTROL VALVE....................................................................................................................................................137
	BUCKET LINKAGE.....................................................................................................................................................................143
	BUCKET.............................................................................................................................................................................145
	BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................................146
	OPERATION OF PROXIMITY SWITCH......................................................................................................................................................148
	CAB................................................................................................................................................................................152
	AIR CONDITIONER....................................................................................................................................................................153
	ELECTRICAL WIRING DIAGRAM CIRCUIT..................................................................................................................................................158
	ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER..................................................................................................................................160
	ELECTRICAL CIRCUIT DIAGRAM FOR AIR GAUGE...........................................................................................................................................161
	ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)........................................................................................................................................162
	ENGINE STARTING CIRCUIT............................................................................................................................................................175
	ENGINE STOP CIRCUIT................................................................................................................................................................176
	PREHEATING CIRCUIT.................................................................................................................................................................177
	COMBINATION SWITCH.................................................................................................................................................................180
	ELECTRICAL TRANSMISSION CONTROL....................................................................................................................................................181
	KICK-DOWN SWITCH...................................................................................................................................................................185
	ELECTRICAL PARKING BRAKE CONTROL...................................................................................................................................................192
20 TESTING AND ADJUSTING...............................................................................................................................................................201
	STANDARD VALUE TABLE FOR ENGINE....................................................................................................................................................202
	STANDARD VALUE TABLE FOR CHASSIS...................................................................................................................................................204
	STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.........................................................................................................................................207
	TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................210
	ADJUSTING VALVE CLEARANCE..........................................................................................................................................................212
	MEASURING COMPRESSION PRESSURE.....................................................................................................................................................213
	TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................................................................................................214
	MEASURING EXHAUST GAS COLOR........................................................................................................................................................216
	MEASURING BLOW-BY PRESSURE.........................................................................................................................................................218
	MEASURING ENGINE OIL PRESSURE AND TEMPERATURE......................................................................................................................................219
	TESTING AND ADJUSTING BELT TENSION.................................................................................................................................................220
	MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE....................................................................................................................221
	MEASURING SHIFT LEVER..............................................................................................................................................................223
	MEASURING ENGINE STALL SPEED.......................................................................................................................................................224
	MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION........................................................................................................................226
	METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL.....................................................................................................................................229
	TIRE AND WHEEL.....................................................................................................................................................................231
	MEASURING STEERING WHEEL PLAY......................................................................................................................................................232
	MEASURING OPERATING FORCE OF STEERING WHEEL........................................................................................................................................233
	OPERATING TIME OF STEERING WHEEL...................................................................................................................................................234
	TESTING AND ADJUSTING STEERING LINKAGE.............................................................................................................................................235
	STEERING OIL PRESSURE..............................................................................................................................................................238
	MEASURING BRAKE PEDAL..............................................................................................................................................................240
	MEASURING AIR PRESSURE.............................................................................................................................................................241
	BRAKE PERFORMANCE..................................................................................................................................................................244
	CHECKING BRAKE PISTON LEAKAGE......................................................................................................................................................245
	MEASURING WEAR OF BRAKE DISC.......................................................................................................................................................246
	AIR BLEEDING FROM BRAKE LINE.......................................................................................................................................................247
	PARKING BRAKE PERFORMANCE..........................................................................................................................................................248
	CHECKING AND ADJUSTING PARKING BRAKE...............................................................................................................................................249
	MEASURING DUMP AND LIFT CONTROL LEVERS.............................................................................................................................................251
	MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT.....................................................................................................................................254
	MEASURING WORK EQUIPMENT...........................................................................................................................................................257
	MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT........................................................................................................................................258
	ADJUSTING BUCKET POSITIONER........................................................................................................................................................259
	ADJUSTING BOOM KICK-OUT............................................................................................................................................................260
	ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR....................................................................................................................................261
	TROUBLESHOOTING....................................................................................................................................................................262
		ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................................................................263
		ELECTRICAL WIRING DIAGRAM......................................................................................................................................................267
		CONNECTOR TERMINAL NUMBERS.....................................................................................................................................................268
		PRECAUTION WHEN HANDLING CONNECTOR.............................................................................................................................................273
		TROUBLESHOOTING PROCEDURE......................................................................................................................................................275
		CHECK BEFORE TROUBLESHOOTING...................................................................................................................................................276
		JUDGEMENT ON POWER TRAIN.......................................................................................................................................................277
		METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART..............................................................................................................................278
		METHOD OF READING TROUBLESHOOTING TABLE........................................................................................................................................280
		TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM......................................................................................................................................282
			POSITION OF CONNECTORS FOR TROUBLESHOOTING.................................................................................................................................283
			E-1. ENGINE DOES NOT START.................................................................................................................................................291
			E-2. ENGINE DOES NOT STOP..................................................................................................................................................295
			E-3. ENGINE STOPS WHEN TRAVELING...........................................................................................................................................295
			E-4. PARKING BRAKE DOES NOT WORK...........................................................................................................................................296
			E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING...............................................................................................................................297
			E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...........................................................................................................299
			E-7. WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL (PARKING BRAKE IS WORKING NORMALLY).................................................................299
			E-8. TRANSMISSION DOES NOT WORK NORMALLY...................................................................................................................................300
			E-9. KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1-F4 SWITCHES CORRECTLY)......................................................................................................320
			E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION).....................................................323
			E-11. KICK-DOWN OPERATION IS NOT CANCELED .................................................................................................................................324
			E-12. KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2......................................................................................................................326
			E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.............................................................................................................326
			E-14. PREHEAT DISPLAY STAYS ON.............................................................................................................................................328
			E-15. PREHEATING DOES NOT STOP.............................................................................................................................................328
		TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM.................................................................................................................329
			CONNECTOR TYPES AND LOCATION OF COMPONENTS.................................................................................................................................331
			M-1. (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED......................................................................................................................342
			M-2. (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED.....................................................................................................................342
			M-3. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED.................................................................................................................344
			M-4. (BATTERY CHARGE ) FLASHES WHEN ENGINE IS RUNNING......................................................................................................................344
			M-5. (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING.....................................................................................................346
			M-6. (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING...........................................................................................................................347
			M-7. (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING...................................................................................................................347
			M-8. (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING..................................................................................................................349
			M-9. (RADIATOR WATER LEVER) FLASHES WHEN ENGINE IS RUNNING.................................................................................................................349
			M-10. (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING................................................................................................................351
			M-11. (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING............................................................................................................351
			M-12. (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING....................................................................................................351
			M-13. (PARKING BRAKE) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP ..........................................................................................................353
				a) IF STAYS LIGHTED UP.................................................................................................................................................353
				b) IF DOES NOT LIGHT UP................................................................................................................................................353
			M-14. (WORKING LAMP) LIGHTS UP ABNORMALLY,OR DOES NOT LIGHT UP.............................................................................................................355
				a) IF STAYS LIGHTED UP.................................................................................................................................................355
				b) IF DOES NOT LIGHT UP................................................................................................................................................355
			M-15. (PREHEATING ) LIGHTS UP,OR DOES NOT LIGHT UP.........................................................................................................................357
				a) (PREHEATING) LIGHTS UP..............................................................................................................................................357
				b) (PREHEATING) DOES NOT LIGHT UP......................................................................................................................................357
			M-16. (TRANSMISSION CUT-OFF) LIGHTS UP, OR DOES NOT LIGHT UP ..............................................................................................................359
				a) LIGHTS UP...........................................................................................................................................................359
				b) DOES NOT LIGHT UP...................................................................................................................................................359
			M-17. TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP.....................................................................................................................361
				a) TURN SIGNAL (RIGHT) PILOT DISPLAY LIGHTS UP.........................................................................................................................361
				b) TURN SIGNAL (LEFT) PILOT DISPLAY LIGHTS UP..........................................................................................................................362
				c) TURN SIGNAL (RIGHT) PILOT DISPLAY DOES NOT LIGHT UP.................................................................................................................363
				d) TURN SIGNAL (LEFT) PILOT DISPLAY DOES NOT LIGHT UP..................................................................................................................363
				e) HI BEAM PILOT DOES NOT LIGHT UP.....................................................................................................................................364
				f) HI BEAM PILOT STAYS LIGHTED UP......................................................................................................................................364
			M-18. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON......................................................................................................366
			M-19. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...........................................................................................................................367
			M-20. HOURMETER DOES NOT WORK NORMALLY.....................................................................................................................................368
			M-21. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS...................................................................................369
				a) NONE OF MONITOR PANEL LIGHTS UP.....................................................................................................................................369
				b) EXCEPT FOR SPEEDOMETER MODULE, NONE OF MONITOR PANEL LIGHTS UP......................................................................................................369
				c) NONE OF CAUTION ITEMS LIGHT UP......................................................................................................................................370
				d) SOME OTHER PARTS DO NOT LIGHT UP....................................................................................................................................370
			M-22. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP,BUT DOES NOT GO OUT...................................................................................370
			M-23. (ENGINE OIL PRESSURE) FLASHES OR (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED.....................................................................................371
				a) (ENGINE OIL PRESSURE) FLASHES, AND ALARM BUZZER AND WARNING LAMP ARE ACTUATED.......................................................................................371
				b) (BATTERY CHARGE)FLASHES, AND WARNING LAMP LIGHTS UP.................................................................................................................371
			M-24. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP,OR PART DOES NOT LIGHT UP...........................................................................................373
				a) EVEN WHEN COMBINATION LAMP IS PLACED AT SMALL, NONE OF PANEL LIGHTING LIGHTS UP.....................................................................................373
				b) EVEN WHEN WORKING LAMP IS SWITCHED ON, NONE OF MONITOR PANEL LIGHTS UP..............................................................................................374
				c) EVEN WHEN STARTING SWITCH IS TURNED ON,NONE OF MONITOR PANEL LIGHTS UP..............................................................................................376
				d) PART OF PANEL DOES NOT LIGHT UP.....................................................................................................................................376
			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 ..................378
			M-26. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS...................................................................................................378
			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....380
			M-28. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP................................................................................................381
			M-29. ABNORMALITY IN (FUEL GAUGE) SYSTEM...................................................................................................................................382
				a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................382
				b) IF INDICATOR REMAINS AT FULL........................................................................................................................................382
			M-30. ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM...........................................................................................................................384
				a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................384
				b) IF INDICATOR REMAINS AT MAXIMUM LEVEL...............................................................................................................................384
			M-31. ABNORMALITY IN (ENGINE WATER TEMPERATURE GAUGE) SYSTEM...............................................................................................................386
				a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................386
				b) IF INDICATOR REMAINS AT MINIMUM LEVEL...............................................................................................................................386
			M-32. ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM.......................................................................................................388
				a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................388
				b) IF INDICATOR REMAINS AT MINIMUM LEVEL...............................................................................................................................388
		TROUBLESHOOTING TABLE FOR HYDRAULIC AND MECHANICAL SYSTEM......................................................................................................................390
			TROUBLESHOOTING TABLE......................................................................................................................................................391
			TORQUE CONVERTER AND TRANSMISSION..........................................................................................................................................391
				T-1.MACHINE DOES NOT MOVE..............................................................................................................................................391
				T-2.MACHINE LACKS POWER OR SPEED.......................................................................................................................................393
				T-3.EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR..........................................................................................................394
				T-4.TORQUE CONVERTER OIL TEMPERATURE TOO HIGH..........................................................................................................................395
			STEERING SYSTEM............................................................................................................................................................396
				S-1. STEERING WHEEL DOES NOT TURN......................................................................................................................................396
				S-2. STEERING WHEEL IS SLUGGISH........................................................................................................................................397
				S-3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK....................................................................................................398
				S-4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING........................................................................................398
				S-5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT........................................................................................................................398
			AIR AND BRAKE SYSTEM.......................................................................................................................................................399
				A-1. AIR PRESSURE DOES NOT RISE AT ALL.................................................................................................................................399
				A-2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE.................................................................................................................400
				A-3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE........................................................................................................................401
				A-4. BRAKE DOES NOT RELEASE, OR DRAGS..................................................................................................................................402
				A-5. PARKING BRAKE DOES NOT RELEASE, OR DRAGS (APPLIES TO MACHINE EQUIPPED WITH AIR PARKING BRAKE).....................................................................403
			WORK EQUIPMENT.............................................................................................................................................................404
				H-1. LIFT ARM DOES NOT RISE............................................................................................................................................404
				H-2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...................................................................................................405
				H-3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT..................................................................................................406
				H-4. BUCKET CANNOT BE HELD DOWN WITH LIFT ARM CYLINDER.................................................................................................................406
				H-5. LIFT ARM HAS LARGE HYDRAULIC DRIFT................................................................................................................................406
				H-6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK.........................................................................................................................406
				H-7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD"TO "RAISE".................................................................................406
				H-8. BUCKET DOES NOT TILT BACK.........................................................................................................................................407
				H-9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...........................................................................................................408
				H-10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK....................................................................................................................409
				H-11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER................................................................................................................409
				H-12. BUCKET HAS LARGE HYDRAULIC DRIFT.................................................................................................................................409
				H-13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD. (MAIN CONTROL VALVE IN "HOLD")..........................................................................409
				H-14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"................................................................................409
				H-15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY..................................................................................................410
30 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................411
	STARTING MOTOR.....................................................................................................................................................................413
		REMOVAL........................................................................................................................................................................413
		INSTALLATION...................................................................................................................................................................413
	ALTERNATOR.........................................................................................................................................................................414
		REMOVAL........................................................................................................................................................................414
		INSTALLATION...................................................................................................................................................................414
	OIL COOLER.........................................................................................................................................................................415
		REMOVAL........................................................................................................................................................................415
		INSTALLATION...................................................................................................................................................................415
	FUEL INJECTION PUMP ...............................................................................................................................................................416
		REMOVAL........................................................................................................................................................................416
		INSTALLATION...................................................................................................................................................................416
	WATER PUMP.........................................................................................................................................................................417
		REMOVAL........................................................................................................................................................................417
		INSTALLATION...................................................................................................................................................................417
	NOZZLE HOLDER......................................................................................................................................................................418
		REMOVAL........................................................................................................................................................................418
		INSTALLATION...................................................................................................................................................................418
	TURBOCHARGER.......................................................................................................................................................................419
		REMOVAL........................................................................................................................................................................419
		INSTALLATION...................................................................................................................................................................419
	AIR COMPRESSOR.....................................................................................................................................................................420
		REMOVAL........................................................................................................................................................................420
		INSTALLATION...................................................................................................................................................................420
	CYLINDER HEAD......................................................................................................................................................................421
		REMOVAL........................................................................................................................................................................421
		INSTALLATION...................................................................................................................................................................426
	RADIATOR...........................................................................................................................................................................432
		REMOVAL........................................................................................................................................................................432
		INSTALLATION...................................................................................................................................................................435
	ENGINE.............................................................................................................................................................................438
		REMOVAL........................................................................................................................................................................438
		INSTALLATION...................................................................................................................................................................444
	DAMPER.............................................................................................................................................................................451
		REMOVAL........................................................................................................................................................................451
		INSTALLATION...................................................................................................................................................................455
		DISASSEMBLY....................................................................................................................................................................459
		ASSEMBLY.......................................................................................................................................................................462
	TORQUE CONVERTER CHARGING PUMP.....................................................................................................................................................466
		REMOVAL........................................................................................................................................................................466
		INSTALLATION...................................................................................................................................................................466
	TORQUE CONVERTER AND TRANSMISSION..................................................................................................................................................467
		REMOVAL........................................................................................................................................................................467
		INSTALLATION...................................................................................................................................................................475
	TORQUE CONVERTER...................................................................................................................................................................484
		DISASSEMBLY....................................................................................................................................................................484
		ASSEMBLY.......................................................................................................................................................................488
	TRANSMISSION.......................................................................................................................................................................493
		DISASSEMBLY....................................................................................................................................................................493
		ASSEMBLY.......................................................................................................................................................................503
	TRANSFER...........................................................................................................................................................................515
		DISASSEMBLY....................................................................................................................................................................515
		ASSEMBLY.......................................................................................................................................................................520
	TRANSMISSION CONTROL VALVE.........................................................................................................................................................526
		REMOVAL........................................................................................................................................................................526
		INSTALLATION...................................................................................................................................................................527
	LOWER VALVE........................................................................................................................................................................528
		DISASSEMBLY....................................................................................................................................................................528
		ASSEMBLY.......................................................................................................................................................................528
	UPPER VALVE........................................................................................................................................................................530
		DISASSEMBLY....................................................................................................................................................................530
		ASSEMBLY.......................................................................................................................................................................530
	MAIN RELIEF VALVE..................................................................................................................................................................532
		DISASSEMBLY....................................................................................................................................................................532
		ASSEMBLY.......................................................................................................................................................................532
	CENTER SUPPORT.....................................................................................................................................................................533
		REMOVAL........................................................................................................................................................................533
		INSTALLATION...................................................................................................................................................................534
		DISASSEMBLY....................................................................................................................................................................535
		ASSEMBLY.......................................................................................................................................................................537
	DRIVE SHAFT .......................................................................................................................................................................539
		DISASSEMBLY (SERIAL NO.20001-20033)............................................................................................................................................539
		ASSEMBLY (SERIAL NO.20001-20033)...............................................................................................................................................541
		DISASSEMBLY (SERIAL NO.20034 AND UP)...........................................................................................................................................543
		ASSEMBLY (SERIAL NO.20034 AND UP)..............................................................................................................................................545
	FRONT AXLE.........................................................................................................................................................................547
		REMOVAL........................................................................................................................................................................547
		INSTALLATION...................................................................................................................................................................549
	FRONT DIFFERENTIAL.................................................................................................................................................................551
		REMOVAL........................................................................................................................................................................551
		INSTALLATION...................................................................................................................................................................554
	REAR AXLE..........................................................................................................................................................................557
		REMOVAL........................................................................................................................................................................557
		INSTALLATION...................................................................................................................................................................561
	REAR DIFFERENTIAL..................................................................................................................................................................565
		REMOVAL........................................................................................................................................................................565
		INSTALLATION...................................................................................................................................................................566
	DIFFERENTIAL GEAR..................................................................................................................................................................568
		DISASSEMBLY....................................................................................................................................................................568
		ASSEMBLY.......................................................................................................................................................................572
	FINAL DRIVE........................................................................................................................................................................579
		DISASSEMBLY....................................................................................................................................................................579
		ASSEMBLY.......................................................................................................................................................................582
	STEERING GEAR......................................................................................................................................................................586
		REMOVAL........................................................................................................................................................................586
		INSTALLATION...................................................................................................................................................................588
	STEERING GEAR BOX..................................................................................................................................................................589
		DISASSEMBLY....................................................................................................................................................................589
		ASSEMBLY.......................................................................................................................................................................590
	STEERING PUMP AND PPC PUMP.........................................................................................................................................................593
		REMOVAL........................................................................................................................................................................593
		INSTALLATION...................................................................................................................................................................594
	STEERING VALVE.....................................................................................................................................................................595
		REMOVAL........................................................................................................................................................................595
		INSTALLATION...................................................................................................................................................................597
		DISASSEMBLY....................................................................................................................................................................599
		ASSEMBLY.......................................................................................................................................................................599
	STEERING CYLINDER..................................................................................................................................................................601
		REMOVAL........................................................................................................................................................................601
		INSTALLATION...................................................................................................................................................................603
		DISASSEMBLY....................................................................................................................................................................605
		ASSEMBLY.......................................................................................................................................................................607
	AIR GOVERNOR.......................................................................................................................................................................610
		DISASSEMBLY....................................................................................................................................................................610
		ASSEMBLY.......................................................................................................................................................................611
	BRAKE VALVE........................................................................................................................................................................612
		REMOVAL........................................................................................................................................................................612
		INSTALLATION...................................................................................................................................................................614
		DISASSEMBLY....................................................................................................................................................................616
		ASSEMBLY.......................................................................................................................................................................618
	BRAKE CHAMBER......................................................................................................................................................................620
		REMOVAL........................................................................................................................................................................620
		INSTALLATION...................................................................................................................................................................622
		DISASSEMBLY....................................................................................................................................................................623
		ASSEMBLY.......................................................................................................................................................................626
	SLACK ADJUSTER.....................................................................................................................................................................629
		REMOVAL........................................................................................................................................................................629
		INSTALLATION...................................................................................................................................................................629
		DISASSEMBLY....................................................................................................................................................................630
		ASSEMBLY.......................................................................................................................................................................631
	BRAKE..............................................................................................................................................................................632
		REMOVAL........................................................................................................................................................................632
		INSTALLATION...................................................................................................................................................................634
	BRAKE(FRONT,REAR)..................................................................................................................................................................637
		DISASSEMBLY....................................................................................................................................................................637
		ASSEMBLY.......................................................................................................................................................................640
	SPRING CYLINDER....................................................................................................................................................................644
		REMOVAL........................................................................................................................................................................644
		INSTALLATION...................................................................................................................................................................645
	PARKING BRAKE......................................................................................................................................................................646
		REMOVAL........................................................................................................................................................................646
		INSTALLATION...................................................................................................................................................................649
	PARKING BRAKE PAD .................................................................................................................................................................652
		REMOVAL........................................................................................................................................................................652
		INSTALLATION...................................................................................................................................................................652
	HYDRAULIC TANK.....................................................................................................................................................................653
		REMOVAL........................................................................................................................................................................653
		INSTALLATION...................................................................................................................................................................655
	HYDRAULIC FILTER...................................................................................................................................................................657
		REMOVAL........................................................................................................................................................................657
		INSTALLATION...................................................................................................................................................................657
	HYDRAULIC PUMP.....................................................................................................................................................................658
		REMOVAL........................................................................................................................................................................658
		INSTALLATION...................................................................................................................................................................660
	SWITCH PUMP........................................................................................................................................................................661
		REMOVAL........................................................................................................................................................................661
		INSTALLATION...................................................................................................................................................................663
	PPC VALVE..........................................................................................................................................................................664
		REMOVAL........................................................................................................................................................................664
		INSTALLATION...................................................................................................................................................................666
		DISASSEMBLY....................................................................................................................................................................668
		ASSEMBLY.......................................................................................................................................................................668
	PPC RELIEF VALVE...................................................................................................................................................................669
		DISASSEMBLY....................................................................................................................................................................669
		ASSEMBLY.......................................................................................................................................................................669
	MAIN CONTROL VALVE.................................................................................................................................................................670
		REMOVAL........................................................................................................................................................................670
		INSTALLATION...................................................................................................................................................................673
		DISASSEMBLY....................................................................................................................................................................677
		ASSEMBLY.......................................................................................................................................................................680
	DUMP CYLINDER......................................................................................................................................................................683
		REMOVAL........................................................................................................................................................................683
		INSTALLATION...................................................................................................................................................................685
	LIFT CYLINDER......................................................................................................................................................................687
		REMOVAL........................................................................................................................................................................687
		INSTALLATION...................................................................................................................................................................689
	LIFT AND DUMP CYLINDERS............................................................................................................................................................691
		DISASSEMBLY....................................................................................................................................................................691
		ASSEMBLY.......................................................................................................................................................................693
	CENTER HINGE PIN...................................................................................................................................................................696
		REMOVAL........................................................................................................................................................................696
		INSTALLATION...................................................................................................................................................................703
	WORK EQUIPMENT.....................................................................................................................................................................712
		REMOVAL........................................................................................................................................................................712
		INSTALLATION...................................................................................................................................................................716
	COUNTERWEIGHT......................................................................................................................................................................720
		REMOVAL........................................................................................................................................................................720
		INSTALLATION...................................................................................................................................................................720
	FUEL TANK..........................................................................................................................................................................721
		REMOVAL........................................................................................................................................................................721
		INSTALLATION...................................................................................................................................................................723
	CAB................................................................................................................................................................................725
		REMOVAL........................................................................................................................................................................725
		INSTALLATION...................................................................................................................................................................727
	AIR CONDITIONER UNIT...............................................................................................................................................................728
		REMOVAL........................................................................................................................................................................728
		INSTALLATION...................................................................................................................................................................730
	AIR CONDITIONER CONDENSER..........................................................................................................................................................732
		REMOVAL........................................................................................................................................................................732
		INSTALLATION...................................................................................................................................................................732
	DRY RESERVOIR......................................................................................................................................................................733
		REMOVAL........................................................................................................................................................................733
		INSTALLATION...................................................................................................................................................................733
	COMPRESSOR FOR AIR CONDITIONER.....................................................................................................................................................734
		REMOVAL........................................................................................................................................................................734
		INSTALLATION...................................................................................................................................................................735
	MACHINE MONITOR....................................................................................................................................................................736
		REMOVAL........................................................................................................................................................................736
		INSTALLATION...................................................................................................................................................................737
40 MAINTENANCE STANDARD................................................................................................................................................................738
	ENGINE MOUNT.......................................................................................................................................................................739
	TRANSMISSION MOUNT.................................................................................................................................................................740
	DAMPER.............................................................................................................................................................................741
	TORQUE CONVERTER CHARGING PUMP.....................................................................................................................................................742
	TORQUE CONVERTER AND PTO...........................................................................................................................................................743
	TRANSMISSION.......................................................................................................................................................................744
	TRANSFER...........................................................................................................................................................................748
	TRANSMISSION CONTROL VALVE.........................................................................................................................................................750
	CENTER SUPPORT.....................................................................................................................................................................755
	DRIVE SHAFT........................................................................................................................................................................756
	DIFFERENTIAL.......................................................................................................................................................................757
	FINAL DRIVE........................................................................................................................................................................761
	AXLE MOUNT.........................................................................................................................................................................762
	CENTER HINGE PIN...................................................................................................................................................................764
	STEERING LINKAGE AND STEERING COLUMN...............................................................................................................................................766
	STEERING GEAR BOX..................................................................................................................................................................768
	STEERING PUMP......................................................................................................................................................................769
	STEERING VALVE.....................................................................................................................................................................770
	STEERING CYLINDER MOUNT............................................................................................................................................................772
	BRAKE VALVE........................................................................................................................................................................773
	BRAKE CHAMBER......................................................................................................................................................................775
	SLACK ADJUSTER.....................................................................................................................................................................776
	BRAKE..............................................................................................................................................................................777
	PARKING BRAKE......................................................................................................................................................................779
	SPRING CYLINDER....................................................................................................................................................................780
	HYDRAULIC AND SWITCH PUMP..........................................................................................................................................................781
	PPC PUMP...........................................................................................................................................................................782
	PPC VALVE..........................................................................................................................................................................783
	MAIN CONTROL VALVE.................................................................................................................................................................785
	HYDRAULIC CYLINDERS................................................................................................................................................................787
	BUCKET LINKAGE.....................................................................................................................................................................789
	BUCKET.............................................................................................................................................................................791
	BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................................792

DESCRIPTION:

KOMATSU WA500-1 SHOP MANUAL SEBM0425M102 – PDF DOWNLOAD

S.S 25/12/24