Komatsu WA500-1 Wheel Loader Shop Manual CEBM000500 – PDF DOWNLOAD

Description

Komatsu WA500-1 Wheel Loader Shop Manual

FILE DETAILS:

Komatsu WA500-1 Wheel Loader Shop Manual

Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA500-1
Serial Number: A61001 and up
Book Code: CEBM000500
Language: English
Pages:869
File Format: Portable Document Format (PDF)

DESCRIPTION:

Komatsu WA500-1 Wheel Loader Shop Manual

FOREWORD:

GENERAL:

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. 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 the following chapters; these
  chapters are further divided into the each main group of components.

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.

TABLE OF CONTENTS:

Komatsu WA500-1 Wheel Loader Shop Manual 

MAIN MENU.......................................................................................................................................  0
CONTENTS........................................................................................................................................  2
01 GENERAL...................................................................................................................................... 21
	SPECIFICATION DRAWINGS...................................................................................................................... 22
	SPECIFICATIONS.............................................................................................................................. 24
	WEIGHT TABLE................................................................................................................................ 27
	FUEL, COOLANT, AND LUBRICANTS............................................................................................................... 28
		ENGINE OIL SPECIFICATIONS............................................................................................................... 29
		TRANSMISSION, HYDRAULIC SYSTEM AND BRAKE SYSTEM OIL SPECIFICATIONS...................................................................... 30
		AXLE OIL SPECIFICATIONS................................................................................................................. 30
		GREASE SPECIFICATIONS................................................................................................................... 30
		DIESEL FUEL SPECIFICATIONS.............................................................................................................. 30
		COOLANT SPECIFICATIONS.................................................................................................................. 30
10 STRUCTURE AND FUNCTION....................................................................................................................... 37
	GENERAL..................................................................................................................................... 38
	RADIATOR AND OIL COOLER..................................................................................................................... 40
	DAMPER...................................................................................................................................... 41
	TORQUE CONVERTER AND TRANSMISSION PIPING.................................................................................................... 43
	HYDRAULIC CIRCUIT FOR POWER TRAIN........................................................................................................... 45
	HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN................................................................................................... 47
	TORQUE CONVERTER AND PTO.................................................................................................................... 49
	TRANSMISSION................................................................................................................................ 52
	TRANSMISSION CONTROL VALVE.................................................................................................................. 57
	TRANSMISSION SOLENOID VALVE................................................................................................................. 60
	TRANSMISSION OIL FILTER..................................................................................................................... 77
	TRANSMISSION PILOT OIL FILTER............................................................................................................... 78
	TRANSFER.................................................................................................................................... 79
	DRIVE SHAFT................................................................................................................................. 80
	CENTER SUPPORT.............................................................................................................................. 82
	AXLE........................................................................................................................................ 84
	DIFFERENTIAL................................................................................................................................ 86
	FINAL DRIVE................................................................................................................................. 90
	AXLE MOUNT.................................................................................................................................. 92
	TIRE AND WHEEL.............................................................................................................................. 94
	CENTER HINGE PIN............................................................................................................................ 95
	STEERING PIPING............................................................................................................................. 96
	STEERING CIRCUIT DIAGRAM.................................................................................................................... 97
	STEERING COLUMN AND GEAR BOX................................................................................................................ 98
	STEERING LINKAGE............................................................................................................................ 99
	STEERING VALVE..............................................................................................................................100
	BRAKE AND AIR PIPING........................................................................................................................114
	BRAKE AND AIR CIRCUIT DIAGRAM...............................................................................................................115
	BRAKE AND AIR CIRCUIT SYSTEM................................................................................................................116
	AIR GOVERNOR................................................................................................................................118
	AIR TANK....................................................................................................................................120
	SAFETY VALVE................................................................................................................................122
	BRAKE VALVE.................................................................................................................................123
	TWO-WAY VALVE...............................................................................................................................128
	BRAKE CHAMBER...............................................................................................................................129
	SLACK ADJUSTER..............................................................................................................................131
	CHECK VALVE.................................................................................................................................134
	BRAKE.......................................................................................................................................136
	PARKING BRAKE...............................................................................................................................138
	PARKING BRAKE SOLENOID VALVE................................................................................................................140
	SPRING CYLINDER.............................................................................................................................141
	BRAKE CALIPER...............................................................................................................................142
	HYDRAULIC PIPING............................................................................................................................144
	HYDRAULIC CIRCUIT SYSTEM....................................................................................................................146
	HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................147
	WORK EQUIPMENT LEVER LINKAGE................................................................................................................149
	HYDRAULIC TANK..............................................................................................................................150
	ACCUMULATOR.................................................................................................................................153
	PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE).............................................................................................154
	PPC RELIEF VALVE............................................................................................................................160
	M AIN CONTROL VALVE.........................................................................................................................162
	OPER ATION OF MAIN CONTROL VALVE............................................................................................................170
	BUCKET LINKAGE..............................................................................................................................176
	BUCKET......................................................................................................................................178
	BUCKET POSITIONER AND BOOM KICK-OUT.........................................................................................................180
	AIR GAUGE CIRCUIT DIAGRAM...................................................................................................................188
	CAB.........................................................................................................................................189
	ELECTRICAL CIRCUIT DIAGRAM..................................................................................................................190
	ELECTRICAL CIRCUIT FOR INTERMITTENT WIPER...................................................................................................194
	ELECTRICAL CIRCUIT DIAGRAM FOR AIR GAUGE....................................................................................................195
	ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).................................................................................................196
	SENSORS.....................................................................................................................................202
	ENGINE STARTING CIRCUIT.....................................................................................................................212
	ENGINE STOP CIRCUIT.........................................................................................................................214
	ETHER START CIRCUIT.........................................................................................................................215
	ELECTRIC TRANSMISSION CONTROL...............................................................................................................216
	COMBINATION SWITCH..........................................................................................................................217
	TRANSMISSION CUT-OFF SWITCH.................................................................................................................218
	TRANSMISSION CUT-OFF SELECTOR SWITCH........................................................................................................219
	NEUTRALIZER RELAY...........................................................................................................................220
	KICK-DOWN SWITCH............................................................................................................................221
	KICK-DOWN ELECTRIC CIRCUIT..................................................................................................................222
	ELECTRIC PARKING BRAKE CONTROL..............................................................................................................228
20 TESTING AND ADJUSTING........................................................................................................................237
	STANDARD VALUE TABLE FOR ENGINE.............................................................................................................239
	STANDARD VALUE TABLE FOR CHASSIS............................................................................................................240
	STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM..................................................................................................245
	SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING......................................................................................248
	MEASURING ENGINE SPEEDS.....................................................................................................................251
	MEASURING INTAKE MANIFOLD PRESSURE..........................................................................................................252
	MEASURING INTAKE AIR RESTRICTION............................................................................................................253
	MEASURING ENGINE LUBRICATING OIL PRESSURE...................................................................................................254
	MEASURING FUEL FILTER INLET RESTRICTION.....................................................................................................255
	MEASURING BLOW-BY PRESSURE..................................................................................................................256
	MEASURING EXHAUST BACK PRESSURE.............................................................................................................257
	MEASURING COOLANT TEMPERATURE...............................................................................................................258
	MEASURING AND ADJUSTING VALVE CLEARANCE.....................................................................................................259
	ALTERNATOR FAN BELT.........................................................................................................................261
	MEASURING EXHAUST GAS COLOR.................................................................................................................262
	MEASURING ENGINE STALL SPEEDS...............................................................................................................264
	MEASURING ACCELERATOR PEDAL.................................................................................................................266
	MEASURING SHIFT LEVERS......................................................................................................................268
	MEASURING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE....................................................................................270
	METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL..............................................................................................272
	MEASURING CLEARANCE BETWEEN TIRES AND WHEELS................................................................................................274
	MEASURING STEERING WHEEL PLAY...............................................................................................................275
	MEASURING STEERING WHEEL OPERATING FORCE....................................................................................................276
	OPERATING TIME OF STEERING WHEEL............................................................................................................277
	STEERING OIL PRESSURE.......................................................................................................................278
	STEERING LINKAGE............................................................................................................................280
	MEASURING BRAKE PEDAL.......................................................................................................................283
	MEASURING AIR PRESSURE......................................................................................................................284
	BRAKE PERFORMANCE...........................................................................................................................286
	CHECKING BRAKE OIL PRESSURE.................................................................................................................287
	MEASURING WEAR OF BRAKE DISCS...............................................................................................................288
	BLEEDING AIR FROM BRAKE LINE................................................................................................................289
	PARKING BRAKE PERFORMANCE...................................................................................................................291
	CHECKING AND ADJUSTING PARKING BRAKE........................................................................................................292
	MEASURING DUMP AND LIFT CONTROL LEVERS......................................................................................................295
	ADJUSTING DUMP AND LIFT CONTROL LEVERS......................................................................................................296
	HYDRAULIC CIRCUIT FLUSHING..................................................................................................................298
	PPC RELIEF VALVE PRESSURE...................................................................................................................302
	WORK EQUIPMENT RELIEF VALVE.................................................................................................................304
	MEASURING WORK EQUIPMENT OPERATING SPEEDS...................................................................................................306
	MEASURING WORK EQUIPMENT HYDRAULIC DRIFT....................................................................................................307
	BUCKET POSITIONER...........................................................................................................................308
	BOOM KICK-OUT...............................................................................................................................309
	MACHINE MONITOR (SPEEDOMETER MODULE)........................................................................................................310
	TROUBLESHOOTING.............................................................................................................................311
		POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................................314
		SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................................................315
		PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...............................................................................................316
		HANDLING CONNECTORS.....................................................................................................................323
		CHECKS BEFORE TROUBLESHOOTING...........................................................................................................324
		PRECAUTIONS WHEN TROUBLESHOOTING........................................................................................................325
		METHOD OF READING TROUBLESHOOTING TABLES................................................................................................327
		PREVENTING RECURRENCE OF TROUBLE........................................................................................................329
		JUDGEMENT ON POWER TRAIN (T-1 -T-4).....................................................................................................330
		TROUBLESHOOTING TABLES (POWER TRAIN, T-1 - T-4).........................................................................................332
			Machine does not move (T-1).........................................................................................................332
			Machine lacks power or speed  (T-2).................................................................................................334
			Excessive time lag when starting machine or shifting gear (T-3).....................................................................335
			Torque converter oil temperature too high (T-4).....................................................................................336
		TROUBLESHOOTING TABLES (STEERING).......................................................................................................337
			1. Steering wheel does not turn.....................................................................................................337
			2. Steering wheel is sluggish.......................................................................................................338
			3. Steering wheel moves unsteadily or is subject to large shock.....................................................................339
			4. Machine tends to turn naturally in one particular direction when traveling.......................................................339
			5. Left and right turning radii are different.......................................................................................339
		TROUBLESHOOTING TABLES (BRAKE AND AIR SYSTEM)...........................................................................................340
			1. Air pressure does not rise at all................................................................................................340
			2. Air pressure does not rise to the specified range................................................................................341
			3. Brake is ineffective or not very effective.......................................................................................342
			4. Brake does not release, or drags.................................................................................................343
			5. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.)..................................344
		TROUBLESHOOTING TABLES (WORK EQUIPMENT SYSTEM)..........................................................................................345
			1. Lift arm does not rise...........................................................................................................345
			2. Lift arm moves slowly or does not have sufficient lifting power..................................................................346
			3. Lift arm movement becomes slow after it reaches a certain height.................................................................347
			4. Bucket cannot be held down with lift arm cylinder................................................................................347
			5. Lift arm has large hydraulic drift...............................................................................................347
			6. Lift arm movement is unsteady during work........................................................................................347
			7. Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise”...............................................347
			8. Bucket does not tilt back........................................................................................................348
			9. Bucket moves slowly or has insufficient tilt back power..........................................................................349
			10. Bucket movement becomes slow during tilt back...................................................................................350
			11. Bucket cannot be held down by the bucket cylinder...............................................................................350
			12. Bucket has large hydraulic drift................................................................................................350
			13. Bucket moves unsteadily when machine travels under load. (Main control valve in “Hold”).........................................350
			14. Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back”...............................................350
			15. Control levers of lift arm and dump move stiffly and sluggishly.................................................................351
		TROUBLESHOOTING (ELECTRICAL SYSTEM).....................................................................................................352
			JUDGMENT ON POWER TRAIN (ELECTRICAL E-8 - E-13).....................................................................................352
			METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART...................................................................................354
			PRECAUTION WHEN HANDLING CONNECTORS.................................................................................................356
			CONNECTOR TERMINAL NUMBERS..........................................................................................................358
			ELECTRICAL WIRING AND (CN) DIAGRAM..................................................................................................364
			VEHICLE MONITOR SYSTEM..............................................................................................................365
			ELECTRICAL CIRCUIT SYSTEM...........................................................................................................366
				ENGINE STARTING AND STOP CIRCUIT SYSTEM.........................................................................................366
				PARKING BRAKE SYSTEM............................................................................................................367
				KICK-DOWN CIRCUIT SYSTEM........................................................................................................368
				ETHER INJECTION CIRCUIT SYSTEM..................................................................................................369
		TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM...............................................................................................370
			POSITION OF CONNECTORS FOR TROUBLESHOOTING..........................................................................................371
			E-1 ENGINE DOES NOT START...........................................................................................................378
			E-2 ENGINE DOES NOT STOP............................................................................................................380
			E-3 ENGINE STOPS WHEN TRAVELING.....................................................................................................381
			E-4 PARKING BRAKE DOES NOT WORK.....................................................................................................382
			E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING.........................................................................................384
			E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.....................................................................386
			E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL...............................................................386
			E-8 TRANSMISSION DOES NOT WORK NORMALLY.............................................................................................388
			E-9 KICK-DOWN SWITCH DOES NOT WORK..................................................................................................410
			E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON...............................................................................413
			E-11 KICK-DOWN OPERATION IS NOT CANCELED............................................................................................414
			E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2................................................................................416
			E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.......................................................................416
		TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM..........................................................................419
			POSITION OF CONNECTORS FOR TROUBLESHOOTING..........................................................................................420
			M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED................................................................................432
			M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED...............................................................................433
			M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED...........................................................................434
			M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING.................................................................................434
			M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING...............................................................436
			M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING.....................................................................................438
			M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING.............................................................................438
			M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING............................................................................440
			M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING...........................................................................440
			M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING..........................................................................442
			M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING......................................................................442
			M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING..............................................................442
			M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP......................................................................444
			M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP......................................................................446
			M-15 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP............................................................................448
			M-16 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT UP............................................................................450
			M-17 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON................................................................455
			M-18 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.....................................................................................456
			M-19 HOURMETER DISPLAY DOES NOT WORK NORMALLY.......................................................................................457
			M-20 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS.............................................458
			M-21 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT........................................459
			M-22 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED...............................................460
			M-23 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP.........................................462
			M-24 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC................468
			M-25 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS....................................................468
			M-26 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. T....470
			M-27 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP.................................................471
			M-28 ABNORMALITY IN THE FUEL GAUGE SYSTEM...........................................................................................472
			M-29 ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM...................................................................................474
			M-30 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM.......................................................................476
			M-31 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM...............................................................478
		TROUBLESHOOTING (AIR CONDITIONING)......................................................................................................480
30 DISASSEMBLY AND ASSEMBLY.....................................................................................................................485
	STARTING MOTOR ASSEMBLY ....................................................................................................................487
		REMOVAL.................................................................................................................................487
		INSTALLATION............................................................................................................................487
	ALTERNATOR ASSEMBLY ........................................................................................................................488
		REMOVAL.................................................................................................................................488
		INSTALLATION............................................................................................................................488
	ENGINE OIL COOLER ..........................................................................................................................489
		REMOVAL.................................................................................................................................489
		INSTALLATION............................................................................................................................489
	FUEL INJECTION PUMP ASSEMBLY ...............................................................................................................490
		REMOVAL.................................................................................................................................490
		INSTALLATION............................................................................................................................490
	WATER PUMP ASSEMBLY ........................................................................................................................491
		REMOVAL.................................................................................................................................491
		INSTALLATION............................................................................................................................491
	INJECTOR ASSEMBLY ..........................................................................................................................492
		REMOVAL.................................................................................................................................492
		INSTALLATION............................................................................................................................492
	TURBOCHARGER ASSEMBLY ......................................................................................................................493
		REMOVAL.................................................................................................................................493
		INSTALLATION............................................................................................................................493
	AFTER COOLER ASSEMBLY ......................................................................................................................494
		REMOVAL.................................................................................................................................494
		INSTALLATION............................................................................................................................495
	AIR COMPRESSOR ASSEMBLY ....................................................................................................................496
		REMOVAL.................................................................................................................................496
		INSTALLATION............................................................................................................................497
	CYLINDER HEAD ASSEMBLY .....................................................................................................................498
		REMOVAL.................................................................................................................................498
		INSTALLATION............................................................................................................................500
	RADIATOR ASSEMBLY ..........................................................................................................................503
		REMOVAL.................................................................................................................................503
		INSTALLATION............................................................................................................................506
	ENGINE .....................................................................................................................................509
		REMOVAL.................................................................................................................................509
		INSTALLATION............................................................................................................................515
	DAMPER ASSEMBLY ............................................................................................................................522
		REMOVAL.................................................................................................................................522
		INSTALLATION............................................................................................................................526
		DISASSEMBLY.............................................................................................................................530
		ASSEMBLY................................................................................................................................533
	FUEL TANK ASSEMBLY .........................................................................................................................538
		REMOVAL.................................................................................................................................538
		INSTALLATION............................................................................................................................540
	TORQUE CONVERTER CHARGING AND PPC PUMP .....................................................................................................542
		REMOVAL.................................................................................................................................542
		INSTALLATION............................................................................................................................543
	TORQUE CONVERTER  AND  TRANSMISSION ........................................................................................................544
		REMOVAL.................................................................................................................................544
		INSTALLATION............................................................................................................................552
	TORQUE CONVERTER ASSEMBLY ..................................................................................................................562
		DISASSEMBLY.............................................................................................................................562
		ASSEMBLY ...............................................................................................................................566
	TRANSMISSION ASSEMBLY ......................................................................................................................571
		DISASSEMBLY.............................................................................................................................571
		ASSEMBLY ...............................................................................................................................581
	TRANSFER CASE ASSEMBLY .....................................................................................................................593
		DISASSEMBLY.............................................................................................................................593
		ASSEMBLY................................................................................................................................598
	TRANSMISSION CONTROL VALVE .................................................................................................................604
		REMOVAL.................................................................................................................................604
		INSTALLATION............................................................................................................................605
	LOWER VALVE ASSEMBLY .......................................................................................................................606
		DISASSEMBLY.............................................................................................................................607
		ASSEMBLY................................................................................................................................607
	UPPER VALVE ASSEMBLY .......................................................................................................................608
		DISASSEMBLY.............................................................................................................................609
		ASSEMBLY................................................................................................................................609
	MAIN RELIEF VALVE ASSEMBLY .................................................................................................................610
		DISASSEMBLY.............................................................................................................................610
		ASSEMBLY................................................................................................................................610
	CENTER SUPPORT .............................................................................................................................612
		REMOVAL.................................................................................................................................612
		INSTALLATION............................................................................................................................613
		DISASSEMBLY.............................................................................................................................614
		ASSEMBLY................................................................................................................................616
	DRIVE SHAFT ................................................................................................................................618
		DISASSEMBLY.............................................................................................................................618
		ASSEMBLY................................................................................................................................620
	FRONT AXLE .................................................................................................................................622
		REMOVAL.................................................................................................................................622
		INSTALLATION............................................................................................................................624
	FRONT DIFFERENTIAL .........................................................................................................................626
		REMOVAL.................................................................................................................................626
		INSTALLATION............................................................................................................................629
	REAR AXLE ..................................................................................................................................632
		REMOVAL.................................................................................................................................632
		INSTALLATION............................................................................................................................636
	REAR DIFFERENTIAL ..........................................................................................................................640
		REMOVAL.................................................................................................................................640
		INSTALLATION............................................................................................................................641
	DIFFERENTIAL GEAR ASSEMBLY .................................................................................................................643
		DISASSEMBLY.............................................................................................................................643
		ASSEMBLY ...............................................................................................................................647
	FINAL DRIVE ................................................................................................................................654
		DISASSEMBLY.............................................................................................................................654
		ASSEMBLY................................................................................................................................657
	STEERING GEAR ..............................................................................................................................661
		REMOVAL.................................................................................................................................661
		INSTALLATION............................................................................................................................663
	STEERING GEAR BOX ..........................................................................................................................664
		DISASSEMBLY.............................................................................................................................664
		ASSEMBLY................................................................................................................................665
	STEERING AND PPC PUMP ......................................................................................................................668
		REMOVAL.................................................................................................................................668
		INSTALLATION............................................................................................................................669
	STEERING VALVE .............................................................................................................................670
		REMOVAL.................................................................................................................................670
		INSTALLATION............................................................................................................................672
		DISASSEMBLY.............................................................................................................................674
		ASSEMBLY................................................................................................................................675
	STEERING CYLINDER ..........................................................................................................................676
		REMOVAL.................................................................................................................................676
		INSTALLATION............................................................................................................................678
		DISASSEMBLY.............................................................................................................................680
		ASSEMBLY................................................................................................................................682
	CENTER HINGE PIN ...........................................................................................................................685
		REMOVAL.................................................................................................................................685
		INSTALLATION............................................................................................................................692
	AIR GOVERNOR ...............................................................................................................................702
		DISASSEMBLY.............................................................................................................................702
		ASSEMBLY................................................................................................................................703
	BRAKE VALVE ................................................................................................................................704
		REMOVAL.................................................................................................................................704
		INSTALLATION............................................................................................................................706
		DISASSEMBLY.............................................................................................................................708
		ASSEMBLY................................................................................................................................710
	BRAKE CHAMBER ..............................................................................................................................712
		REMOVAL.................................................................................................................................712
		INSTALLATION............................................................................................................................714
		DISSASEMBLY.............................................................................................................................715
		ASSEMBLY................................................................................................................................718
	SLACK ADJUSTER .............................................................................................................................721
		REMOVAL.................................................................................................................................721
		INSTALLATION............................................................................................................................721
		DISASSEMBLY.............................................................................................................................722
		ASSEMBLY................................................................................................................................723
	BRAKE ASSEMBLY .............................................................................................................................724
		REMOVAL.................................................................................................................................724
		INSTALLATION............................................................................................................................726
		DISASSEMBLY.............................................................................................................................730
		ASSEMBLY................................................................................................................................733
	SPRING CYLINDER ............................................................................................................................737
		REMOVAL.................................................................................................................................737
		INSTALLATION............................................................................................................................738
	PARKING BRAKE ..............................................................................................................................739
		REMOVAL.................................................................................................................................739
		INSTALLATION............................................................................................................................742
	PARKING BRAKE PAD ..........................................................................................................................745
		REMOVAL.................................................................................................................................745
		INSTALLATION............................................................................................................................745
	HYDRAULIC TANK .............................................................................................................................746
		REMOVAL.................................................................................................................................746
		INSTALLATION............................................................................................................................748
	HYDRAULIC FILTER ...........................................................................................................................750
		REMOVAL.................................................................................................................................750
		INSTALLATION............................................................................................................................750
	WORK EQUIPMENT PUMP ........................................................................................................................751
		REMOVAL.................................................................................................................................751
		INSTALLATION............................................................................................................................753
	SWITCH PUMP ................................................................................................................................754
		REMOVAL.................................................................................................................................754
		INSTALLATION............................................................................................................................756
	PPC VALVE ASSEMBLY .........................................................................................................................757
		REMOVAL.................................................................................................................................757
		INSTALLATION............................................................................................................................759
		DISASSEMBLY.............................................................................................................................761
		ASSEMBLY................................................................................................................................761
	PPC RELIEF VALVE ASSEMBLY ..................................................................................................................762
		DISASSEMBLY.............................................................................................................................762
		ASSEMBLY................................................................................................................................762
	MAIN CONTROL VALVE .........................................................................................................................763
		REMOVAL.................................................................................................................................763
		INSTALLATION............................................................................................................................766
		DISASSEMBLY.............................................................................................................................770
		ASSEMBLY................................................................................................................................774
	DUMP CYLINDER ..............................................................................................................................778
		REMOVAL.................................................................................................................................778
		INSTALLATION............................................................................................................................780
	LIFT CYLINDER ..............................................................................................................................782
		REMOVAL.................................................................................................................................782
		INSTALLATION............................................................................................................................784
	LIFT AND DUMP CYLINDERS ....................................................................................................................786
		DISASSEMBLY.............................................................................................................................786
		ASSEMBLY................................................................................................................................788
	WORK EQUIPMENT .............................................................................................................................792
		REMOVAL.................................................................................................................................792
		INSTALLATION............................................................................................................................796
	COUNTERWEIGHT ..............................................................................................................................800
		REMOVAL.................................................................................................................................800
		INSTALLATION............................................................................................................................800
	MACHINE MONITOR ............................................................................................................................802
		REMOVAL.................................................................................................................................802
		INSTALLATION............................................................................................................................803
40 MAINTENANCE STANDARD.........................................................................................................................805
	ENGINE MOUNT................................................................................................................................806
	TRANSMISSION MOUNT..........................................................................................................................807
	TORQUE CONVERTER CHARGING PUMP..............................................................................................................808
	DAMPER......................................................................................................................................810
	TORQUE CONVERTER AND PTO....................................................................................................................812
	TRANSMISSION................................................................................................................................814
	TRANSMISSION CONTROL VALVE..................................................................................................................818
		UPPER VALVE ASSEMBLY....................................................................................................................818
		LOWER VALVE ASSEMBLY....................................................................................................................820
		SOLENOID VALVE ASSEMBLY.................................................................................................................822
	TRANSFER....................................................................................................................................824
	DIFFERENTIAL................................................................................................................................826
	FINAL DRIVE.................................................................................................................................830
	DRIVE SHAFT.................................................................................................................................831
	CENTER SUPPORT..............................................................................................................................832
	AXLE MOUNT..................................................................................................................................834
	BRAKE VALVE.................................................................................................................................836
	BRAKE CHAMBER...............................................................................................................................838
	SLACK ADJUSTER..............................................................................................................................839
	BRAKE.......................................................................................................................................840
	PARKING BRAKE...............................................................................................................................842
	SPRING CYLINDER.............................................................................................................................844
	CENTER HINGE PIN............................................................................................................................846
	STEERING LINKAGE AND COLUMN.................................................................................................................848
	STEERING GEAR BOX...........................................................................................................................850
	STEERING PUMP...............................................................................................................................851
	STEERING VALVE..............................................................................................................................852
	STEERING CYLINDER MOUNT.....................................................................................................................855
	HYDRAULIC AND SWITCH PUMP...................................................................................................................856
	PPC PUMP....................................................................................................................................857
	PPC VALVE...................................................................................................................................858
	MAIN CONTROL VALVE..........................................................................................................................860
	HYDRAULIC CYLINDERS.........................................................................................................................862
	BUCKET LINKAGE..............................................................................................................................864
	BUCKET POSITIONER AND BOOM KICK-OUT.........................................................................................................866
	BUCKET......................................................................................................................................867

KOMATSU WA500-1 WHEEL LOADER SHOP MANUAL CEBM000500 – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.