Komatsu WA500-1 Wheel Loader Shop Manual CEBM000500 PDF

Description

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

FILE DETAILS:

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

Language : English
Pages : 869
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

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

SERIAL NUMBERS VVA500-1 LE – A61001 and UP

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

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

SERIAL NUMBERS VVA500-1 LE – A61001 and UP

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

S.V 14/12/24