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Komatsu WA500-1LC Wheel Loader Shop Manual CEBMW25050 – PDF DOWNLOAD
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Komatsu WA500-1LC Wheel Loader Shop Manual
MACHINE MODEL SERIAL NUMBERS
WA500-1 LC A60001 and up
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Description
Komatsu WA500-1LC Wheel Loader Shop Manual CEBMW25050
FILE DETAILS:
Komatsu WA500-1LC Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA500-1LC
Serial Number: A60001 and up
Book Code: CEBMW25050
Language: English
Pages: 959
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA500-1LC 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 WA500-1LC Wheel Loader Shop Manual
MAIN MENU....................................................................................................................................... 0 CONTENTS........................................................................................................................................ 5 10 ENGINE....................................................................................................................................... 19 12 TESTING AND ADJUSTING.................................................................................................................... 19 STANDARD VALUE TABLE.................................................................................................................... 20 FOR ENGINE ON TEST BENCH............................................................................................................ 20 FOR ENGINE ON CHASSIS............................................................................................................... 21 TOOL LIST FOR ENGINE.................................................................................................................... 22 MEASURING ENGINE STALL SPEED............................................................................................................ 23 Measuring torque converter stall.................................................................................................... 23 Measuring hydraulic stall........................................................................................................... 24 Measuring full stall................................................................................................................ 24 VALVE CLEARANCE......................................................................................................................... 25 VALVE AND FIXED INJECTORS............................................................................................................... 26 BLOW-BY PRESSURE........................................................................................................................ 27 ALTERNATOR FAN BELT..................................................................................................................... 28 EXHAUST GAS COLOR....................................................................................................................... 29 OIL PRESSURE............................................................................................................................ 31 OIL TEMPERATURE......................................................................................................................... 32 ACCELERATOR PEDAL....................................................................................................................... 33 OPERATING ANGLE..................................................................................................................... 33 OPERATING FORCE..................................................................................................................... 34 13 DISASSEMBLY AND ASSEMBLY................................................................................................................. 35 STARTING MOTOR ASSEMBLY................................................................................................................. 37 REMOVAL............................................................................................................................. 37 INSTALLATION........................................................................................................................ 37 ALTERNATOR ASSEMBLY..................................................................................................................... 38 REMOVAL............................................................................................................................. 38 INSTALLATION........................................................................................................................ 38 OIL COOLER ASSEMBLY..................................................................................................................... 39 REMOVAL............................................................................................................................. 39 INSTALLATION........................................................................................................................ 39 FUEL PUMP ASSEMBLY...................................................................................................................... 40 REMOVAL............................................................................................................................. 40 INSTALLATION........................................................................................................................ 40 WATER PUMP ASSEMBLY..................................................................................................................... 41 REMOVAL............................................................................................................................. 41 INSTALLATION........................................................................................................................ 41 INJECTOR ASSEMBLY....................................................................................................................... 42 REMOVAL............................................................................................................................. 42 INSTALLATION........................................................................................................................ 42 TURBOCHARGER ASSEMBLY................................................................................................................... 43 REMOVAL............................................................................................................................. 43 INSTALLATION........................................................................................................................ 43 AFTERCOOLER ASSEMBLY.................................................................................................................... 44 REMOVAL............................................................................................................................. 44 INSTALLATION........................................................................................................................ 45 AIR COMPRESSOR ASSEMBLY................................................................................................................. 46 REMOVAL............................................................................................................................. 46 INSTALLATION........................................................................................................................ 47 CYLINDER HEAD ASSEMBLY.................................................................................................................. 48 REMOVAL............................................................................................................................. 48 INSTALLATION........................................................................................................................ 50 RADIATOR ASSEMBLY....................................................................................................................... 53 REMOVAL............................................................................................................................. 53 INSTALLATION........................................................................................................................ 56 ENGINE.................................................................................................................................. 59 REMOVAL............................................................................................................................. 59 INSTALLATION........................................................................................................................ 65 DAMPER ASSEMBLY......................................................................................................................... 72 REMOVAL............................................................................................................................. 72 INSTALLATION........................................................................................................................ 76 DISASSEMBLY OF...................................................................................................................... 80 ASSEMBLY OF......................................................................................................................... 83 FUEL TANK ASSEMBLY...................................................................................................................... 87 REMOVAL............................................................................................................................. 87 INSTALLATION........................................................................................................................ 87 14 MAINTENANCE STANDARD..................................................................................................................... 91 ENGINE MOUNT............................................................................................................................ 92 20 POWER TRAIN.................................................................................................................................. 93 21 STRUCTURE AND FUNCTION................................................................................................................... 93 GENERAL................................................................................................................................. 95 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................................... 97 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN........................................................................................... 98 DAMPER.................................................................................................................................. 99 TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................101 RADIATOR AND OIL COOLER.................................................................................................................102 TORQUE CONVERTER AND PTO................................................................................................................103 TORQUE CONVERTER OIL FILTER.............................................................................................................105 TRANSMISSION............................................................................................................................106 TRANSMISSION foldout #7.............................................................................................................107 TRANSMISSION CONTROL VALVE..............................................................................................................111 UPPER VALVE.........................................................................................................................112 LOWER VALVE.........................................................................................................................113 TRANSMISSION SOLENOID VALVE.............................................................................................................114 TRANSMISSION SOLENOID VALVE.........................................................................................................115 EMERGENCY MANUAL SPOOL..............................................................................................................116 FORWARD 1st.........................................................................................................................117 PRIORITY VALVE......................................................................................................................119 MODULATING VALVE AND QUICK RETURN VALVE.............................................................................................120 ACCUMULATOR VALVE...................................................................................................................123 PILOT REDUCING VALVE................................................................................................................125 MAIN RELIEF VALVE...................................................................................................................126 REDUCING VALVE......................................................................................................................127 TORQUE CONVERTER RELIEF VALVE.......................................................................................................128 LUBRICATION BY-PASS VALVE...........................................................................................................129 TRANSMISSION PILOT OIL FILTER...........................................................................................................130 TRANSFER................................................................................................................................131 DRIVE SHAFT.............................................................................................................................132 CENTER SUPPORT..........................................................................................................................133 AXLES...................................................................................................................................134 FRONT...............................................................................................................................134 REAR................................................................................................................................135 DIFFERENTIAL............................................................................................................................136 FRONT...............................................................................................................................136 REAR................................................................................................................................137 TORQUE PROPORTIONING DIFFERENTIAL...................................................................................................139 FINAL DRIVE.............................................................................................................................140 AXLE MOUNT..............................................................................................................................142 TIRE AND WHEEL..........................................................................................................................144 22 TESTING AND ADJUSTING....................................................................................................................145 STANDARD VALUE TABLE....................................................................................................................146 TOOL LIST FOR TESTING AND ADJUSTING.....................................................................................................147 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION.............................................................................148 MEASURING SHIFT LEVER...................................................................................................................150 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL..........................................................................................152 TIRE AND WHEEL..........................................................................................................................154 TROUBLESHOOTING.........................................................................................................................155 PRECAUTIONS WHEN TROUBLESHOOTING....................................................................................................156 METHOD OF READING TROUBLESHOOTING TABLES............................................................................................158 PREVENTING RECURRENCE OF TROUBLE....................................................................................................160 JUDGEMENT ON POWER TRAIN............................................................................................................161 TROUBLESHOOTING TABLE...............................................................................................................163 Machine does not move...........................................................................................................163 Machine lacks power or speed....................................................................................................165 Excessive time lag when starting machine or shifting gear.......................................................................166 Torque converter oil temperature too high.......................................................................................167 23 DISASSEMBLY AND ASSEMBLY.................................................................................................................169 TORQUE CONVERTER CHARGING AND PPC PUMP..................................................................................................171 REMOVAL.............................................................................................................................171 INSTALLATION........................................................................................................................171 TORQUE CONVERTER AND TRANSMISSION.......................................................................................................172 REMOVAL.............................................................................................................................172 INSTALLATION........................................................................................................................180 TORQUE CONVERTER ASSEMBLY...............................................................................................................190 DISASSEMBLY OF......................................................................................................................190 PTO ASSEMBLY....................................................................................................................192 Disassembly of..............................................................................................................192 ASSEMBLY OF.........................................................................................................................194 PTO ASSEMBLY....................................................................................................................194 Assembly of.................................................................................................................194 TRANSMISSION ASSEMBLY...................................................................................................................199 DISASSEMBLY OF......................................................................................................................199 ASSEMBLY OF.........................................................................................................................209 TRANSFER CASE ASSEMBLY..................................................................................................................221 DISASSEMBLY OF......................................................................................................................221 ASSEMBLY OF.........................................................................................................................226 TRANSMISSION CONTROL VALVE..............................................................................................................232 REMOVAL OF..........................................................................................................................232 INSTALLATION OF.....................................................................................................................233 LOWER VALVE ASSEMBLY................................................................................................................234 DISASSEMBLY OF..................................................................................................................235 ASSEMBLY OF.....................................................................................................................235 UPPER VALVE ASSEMBLY................................................................................................................236 DISASSEMBLY OF..................................................................................................................237 ASSEMBLY OF.....................................................................................................................237 MAIN RELIEF VALVE ASSEMBLY..........................................................................................................238 DISASSEMBLY OF..................................................................................................................238 ASSEMBLY OF.....................................................................................................................238 CENTER SUPPORT..........................................................................................................................239 REMOVAL OF..........................................................................................................................239 INSTALLATION OF.....................................................................................................................240 DISASSEMBLY OF......................................................................................................................241 ASSEMBLY OF.........................................................................................................................243 DRIVE SHAFT.............................................................................................................................245 DISASSEMBLY OF......................................................................................................................245 ASSEMBLY OF.........................................................................................................................247 FRONT AXLE..............................................................................................................................249 REMOVAL OF..........................................................................................................................249 INSTALLATION OF.....................................................................................................................251 FRONT DIFFERENTIAL......................................................................................................................253 REMOVAL OF..........................................................................................................................253 INSTALLATION OF.....................................................................................................................256 REAR AXLE...............................................................................................................................259 REMOVAL OF..........................................................................................................................259 INSTALLATION OF.....................................................................................................................263 REAR DIFFERENTIAL.......................................................................................................................267 REMOVAL OF..........................................................................................................................267 INSTALLATION OF.....................................................................................................................268 DIFFERENTIAL GEAR ASSEMBLY..............................................................................................................270 DISASSEMBLY OF......................................................................................................................270 FINE DISASSEMBLY OF PINION ASSEMBLY.............................................................................................272 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY.............................................................................273 ASSEMBLY OF.........................................................................................................................274 FINE ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY.....................................................................................274 FINE ASSEMBLY OF PINION ASSEMBLY................................................................................................275 ASSEMBLY OF DIFFERENTIAL ASSEMBLY...................................................................................................276 FINAL DRIVE.............................................................................................................................281 DISASSEMBLY OF......................................................................................................................281 ASSEMBLY OF.........................................................................................................................284 24 MAINTENANCE STANDARD.....................................................................................................................289 TRANSMISSION MOUNT......................................................................................................................290 TORQUE CONVERTER CHARGING PUMP..........................................................................................................291 DAMPER..................................................................................................................................292 TORQUE CONVERTER AND PTO................................................................................................................294 TRANSMISSION............................................................................................................................296 TRANSMISSION CONTROL VALVE..............................................................................................................300 UPPER VALVE.........................................................................................................................300 LOWER VALVE.........................................................................................................................302 SOLENOID VALVE......................................................................................................................304 TRANSFER................................................................................................................................306 DIFFERENTIAL............................................................................................................................308 FINAL DRIVE.............................................................................................................................312 DRIVE SHAFT.............................................................................................................................313 CENTER SUPPORT..........................................................................................................................314 AXLE MOUNT..............................................................................................................................316 40 STEERING SYSTEM..............................................................................................................................319 41 STRUCTURE AND FUNCTION...................................................................................................................319 CENTER HINGE PIN........................................................................................................................320 STEERING PIPING.........................................................................................................................321 STEERING CIRCUIT DIAGRAM................................................................................................................322 STEERING COLUMN AND GEAR BOX............................................................................................................323 STEERING LINKAGE........................................................................................................................324 STEERING CONTROL SYSTEM.................................................................................................................325 STEERING VALVE......................................................................................................................325 ROTOR SEAL..........................................................................................................................327 STEERING RELIEF VALVE...............................................................................................................328 SAFETY VALVE (WITH SUCTION VALVE)...................................................................................................329 OPERATION OF DEMAND SPOOL...........................................................................................................331 OPERATION OF THE STEERING VALVE.....................................................................................................334 TWO-WAY RESTRICTOR VALVE................................................................................................................337 42 TESTING AND ADJUSTING....................................................................................................................339 STANDARD VALUE TABLE....................................................................................................................340 TOOL LIST FOR TESTING AND ADJUSTMENT....................................................................................................340 MEASURING STEERING WHEEL PLAY...........................................................................................................341 MEASURING OPERATING FORCE OF STEERING WHEEL.............................................................................................342 OPERATING TIME OF STEERING WHEEL........................................................................................................343 STEERING OIL PRESSURE...................................................................................................................344 STEERING LINKAGE........................................................................................................................346 TROUBLESHOOTING TABLE...................................................................................................................350 1. Steering wheel does not turn.....................................................................................................350 2. Steering wheel is sluggish.......................................................................................................351 3. Steering wheel moves unsteadily or is subject to large shock.....................................................................352 4. Machine tends to turn naturally in one particular direction when traveling.......................................................352 5. Left and right turning radii are different.......................................................................................352 43 DISASSEMBLY AND ASSEMBLY.................................................................................................................353 STEERING GEAR...........................................................................................................................355 REMOVAL OF..........................................................................................................................355 INSTALLATION OF.....................................................................................................................357 STEERING GEAR BOX.......................................................................................................................358 DISASSEMBLY OF......................................................................................................................358 ASSEMBLY OF.........................................................................................................................359 STEERING AND PPC PUMP...................................................................................................................362 REMOVAL OF..........................................................................................................................362 INSTALLATION OF.....................................................................................................................363 STEERING VALVE..........................................................................................................................364 REMOVAL OF..........................................................................................................................364 INSTALLATION OF.....................................................................................................................366 DISASSEMBLY OF......................................................................................................................368 ASSEMBLY OF.........................................................................................................................369 STEERING CYLINDER.......................................................................................................................370 REMOVAL OF..........................................................................................................................370 INSTALLATION OF.....................................................................................................................372 DISASSEMBLY OF......................................................................................................................374 ASSEMBLY OF.........................................................................................................................376 CENTER HINGE PIN........................................................................................................................379 REMOVAL OF..........................................................................................................................379 INSTALLATION OF.....................................................................................................................386 44 MAINTENANCE STANDARD.....................................................................................................................395 CENTER HINGE PIN........................................................................................................................396 STEERING LINKAGE AND STEERING COLUMN....................................................................................................398 STEERING GEAR BOX.......................................................................................................................400 STEERING PUMP...........................................................................................................................401 STEERING CYLINDER MOUNT.................................................................................................................402 50 BRAKE AND AIR SYSTEM.........................................................................................................................403 51 STRUCTURE AND FUNCTION...................................................................................................................403 GENERAL.................................................................................................................................404 AIR SYSTEM..........................................................................................................................404 BRAKE CIRCUIT.......................................................................................................................404 BRAKE AND AIR PIPING....................................................................................................................405 BRAKE AND AIR CIRCUIT SYSTEM............................................................................................................406 AIR TANK................................................................................................................................407 WET TANK............................................................................................................................407 DRY TANK (UPPER)....................................................................................................................407 DRY TANK (LOWER)....................................................................................................................408 SAFETY VALVE............................................................................................................................409 BRAKE VALVE.............................................................................................................................410 BRAKE ACTUATED......................................................................................................................411 OPERATING IN BALANCE................................................................................................................412 BRAKE RELEASED......................................................................................................................413 AIR GOVERNOR............................................................................................................................414 TWO-WAY VALVE...........................................................................................................................416 BRAKE CHAMBER...........................................................................................................................417 SLACK ADJUSTER..........................................................................................................................419 CHECK VALVE.............................................................................................................................422 BRAKE...................................................................................................................................423 PARKING BRAKE...........................................................................................................................425 PARKING BRAKE SOLENOID VALVE............................................................................................................427 SPRING CYLINDER.........................................................................................................................428 BRAKE CALIPER...........................................................................................................................429 52 TESTING AND ADJUSTING....................................................................................................................431 STANDARD VALUE TABLE....................................................................................................................433 TOOL LIST...............................................................................................................................434 MEASURING BRAKE PEDAL...................................................................................................................435 MEASURING AIR PRESSURE..................................................................................................................436 BRAKE PERFORMANCE.......................................................................................................................439 CHECKING BRAKE OIL PRESSURE.............................................................................................................440 MEASURING WEAR OF BRAKE DISC............................................................................................................441 AIR BLEEDING FROM BRAKE LINE............................................................................................................442 PARKING BRAKE PERFORMANCE...............................................................................................................443 CHECKING AND ADJUSTING PARKING BRAKE....................................................................................................444 TROUBLESHOOTING.........................................................................................................................447 TROUBLESHOOTING TABLE...............................................................................................................448 1. Air pressure does not rise at all................................................................................................448 2. Air pressure does not rise to the specified range................................................................................449 3. Brake is ineffective or not very effective.......................................................................................450 4. Brake does not release, or drags.................................................................................................451 5. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.)..................................452 53 DISASSEMBLY AND ASSEMBLY.................................................................................................................453 BRAKE VALVE.............................................................................................................................455 REMOVAL OF..........................................................................................................................455 INSTALLATION OF.....................................................................................................................457 DISASSEMBLY OF......................................................................................................................459 ASSEMBLY OF.........................................................................................................................461 BRAKE CHAMBER...........................................................................................................................463 REMOVAL OF..........................................................................................................................463 INSTALLATION OF.....................................................................................................................465 DISASSEMBLY OF......................................................................................................................466 ASSEMBLY OF.........................................................................................................................469 SLACK ADJUSTER..........................................................................................................................472 REMOVAL OF..........................................................................................................................472 INSTALLATION OF.....................................................................................................................472 DISASSEMBLY OF......................................................................................................................473 ASSEMBLY OF.........................................................................................................................474 BRAKE ASSEMBLY..........................................................................................................................475 REMOVAL OF..........................................................................................................................475 INSTALLATION OF.....................................................................................................................477 DISASSEMBLY OF (FRONT OR REAR)......................................................................................................481 ASSEMBLY OF (FRONT OR REAR).........................................................................................................484 SPRING CYLINDER.........................................................................................................................488 REMOVAL OF..........................................................................................................................488 INSTALLATION OF.....................................................................................................................489 PARKING BRAKE...........................................................................................................................490 REMOVAL OF..........................................................................................................................490 INSTALLATION OF.....................................................................................................................493 PARKING BRAKE PAD.......................................................................................................................496 REMOVAL OF..........................................................................................................................496 INSTALLATION OF.....................................................................................................................496 54 MAINTENANCE STANDARD.....................................................................................................................497 BRAKE VALVE.............................................................................................................................498 BRAKE CHAMBER...........................................................................................................................500 SLACK ADJUSTER..........................................................................................................................501 BRAKE...................................................................................................................................502 PARKING BRAKE...........................................................................................................................504 SPRING CYLINDER.........................................................................................................................506 60 WORK EQUIPMENT SYSTEM........................................................................................................................507 61 STRUCTURE AND FUNCTION...................................................................................................................507 GENERAL.................................................................................................................................509 HYDRAULIC PIPING........................................................................................................................510 HYDRAULIC CIRCUIT.......................................................................................................................510 SCHEMATICS..........................................................................................................................510 DIAGRAM.............................................................................................................................510 HYDRAULIC TANK..........................................................................................................................511 OIL FILTER BY-PASS VALVE............................................................................................................512 BREATHER............................................................................................................................513 PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE).........................................................................................514 OPERATION OF PPC VALVE..............................................................................................................516 PPC RELIEF VALVE....................................................................................................................520 MAIN CONTROL VALVE......................................................................................................................521 RELIEF VALVE........................................................................................................................524 SAFETY VALVE (with suction valve)...................................................................................................525 SUCTION VALVE.......................................................................................................................526 FLOAT SELECTOR VALVE AND UNLOADER VALVE.............................................................................................527 ACCUMULATOR.............................................................................................................................529 OPERATION OF MAIN CONTROL VALVE.........................................................................................................530 LIFT AND DUMP SPOOLS AT "HOLD"......................................................................................................530 LIFT SPOOL AT "RAISE"...............................................................................................................531 LIFT SPOOL AT "LOWER"...............................................................................................................532 LIFT SPOOL AT "FLOAT"...............................................................................................................533 DUMP SPOOL AT "DUMP"................................................................................................................534 DUMP SPOOL AT "TILT BACK"...........................................................................................................535 BUCKET LINKAGE..........................................................................................................................536 BUCKET..................................................................................................................................538 BUCKET POSITIONER AND BOOM KICK-OUT.....................................................................................................539 Bucket positioner...................................................................................................................540 Boom kick-out.......................................................................................................................540 WORK EQUIPMENT LEVER LINKAGE............................................................................................................541 62 TESTING AND ADJUSTING....................................................................................................................543 STANDARD VALUE TABLE....................................................................................................................545 TOOL LIST...............................................................................................................................546 EMERGENCY MANUAL SPOOL METHOD FOR OPERATION.............................................................................................547 OUTLINE.............................................................................................................................547 OPERATION...........................................................................................................................547 DUMP AND LIFT CONTROL LEVERS............................................................................................................549 MEASURING...........................................................................................................................549 ADJUSTING...........................................................................................................................550 HYDRAULIC CIRCUIT FLUSHING..............................................................................................................552 PPC RELIEF VALVE........................................................................................................................555 MEASURING PRESSURE..................................................................................................................555 ADJUSTING...........................................................................................................................557 WORK EQUIPMENT RELIEF VALVE.............................................................................................................558 MEASURING TIME......................................................................................................................560 HYDRAULIC DRIFT.....................................................................................................................561 BUCKET POSITIONER.......................................................................................................................562 BOOM KICK-OUT...........................................................................................................................563 TROUBLESHOOTING.........................................................................................................................564 TROUBLESHOOTING TABLE...............................................................................................................564 1. Lift arm does not rise.......................................................................................................564 2. Lift arm moves slowly or does not have sufficient lifting power..............................................................565 3. Lift arm movement becomes slow after it reaches a certain height.............................................................566 4. Bucket cannot be held down with lift arm cylinder............................................................................566 5. Lift arm has large hydraulic drift...........................................................................................566 6. Lift arm movement is unsteady during work....................................................................................566 7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise"...........................................566 8. Bucket does not tilt back....................................................................................................567 9. Bucket moves slowly or has insufficient tilt back power......................................................................568 10. Bucket movement becomes slow during tilt back...............................................................................569 11. Bucket cannot be held down by the bucket cylinder...........................................................................569 12. Bucket has large hydraulic drift............................................................................................569 13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold").....................................569 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"...........................................569 15. Control levers of lift arm and dump move stiffly and sluggishly.............................................................570 63 DISASSEMBLY AND ASSEMBLY.................................................................................................................571 HYDRAULIC TANK..........................................................................................................................573 REMOVAL.............................................................................................................................573 INSTALLATION........................................................................................................................575 HYDRAULIC FILTER........................................................................................................................577 REMOVAL.............................................................................................................................577 INSTALLATION........................................................................................................................577 WORK EQUIPMENT PUMP.....................................................................................................................578 REMOVAL.............................................................................................................................578 INSTALLATION........................................................................................................................580 SWITCH PUMP.............................................................................................................................581 REMOVAL.............................................................................................................................581 INSTALLATION........................................................................................................................583 PPC VALVE ASSEMBLY......................................................................................................................584 REMOVAL.............................................................................................................................584 INSTALLATION........................................................................................................................586 DISASSEMBLY.........................................................................................................................588 ASSEMBLY............................................................................................................................588 PPC RELIEF VALVE ASSEMBLY...........................................................................................................589 DISASSEMBLY.....................................................................................................................589 ASSEMBLY........................................................................................................................589 MAIN CONTROL VALVE......................................................................................................................590 REMOVAL.............................................................................................................................590 INSTALLATION........................................................................................................................593 DISASSEMBLY.........................................................................................................................598 ASSEMBLY............................................................................................................................602 DUMP CYLINDER...........................................................................................................................605 REMOVAL.............................................................................................................................605 INSTALLATION........................................................................................................................607 LIFT CYLINDER...........................................................................................................................609 INSTALLATION........................................................................................................................611 LIFT AND DUMP CYLINDERS.................................................................................................................613 DISASSEMBLY.........................................................................................................................613 ASSEMBLY............................................................................................................................615 WORK EQUIPMENT..........................................................................................................................618 REMOVAL.............................................................................................................................618 INSTALLATION........................................................................................................................622 COUNTERWEIGHT...........................................................................................................................626 REMOVAL.............................................................................................................................626 INSTALLATION........................................................................................................................626 64 MAINTENANCE STANDARD.....................................................................................................................627 BUCKET LINKAGE..........................................................................................................................628 BUCKET POSITIONER AND BOOM KICK-OUT.....................................................................................................630 BUCKET..................................................................................................................................631 80 ELECTRIC AND ELECTRONIC SYSTEM...............................................................................................................633 81 STRUCTURE AND FUNCTION...................................................................................................................633 ELECTRICAL WIRING DIAGRAM...............................................................................................................635 ENGINE STARTING CIRCUIT.................................................................................................................639 ENGINE STOP CIRCUIT.....................................................................................................................641 ELECTRICAL TRANSMISSION CONTROL.........................................................................................................642 COMBINATION SWITCH..................................................................................................................643 TRANSMISSION CUT-OFF SWITCH.........................................................................................................644 TRANSMISSION CUT-OFF SELECTOR SWITCH................................................................................................645 NEUTRALIZER RELAY...................................................................................................................646 KICK-DOWN SWITCH....................................................................................................................647 KICK-DOWN ELECTRIC CIRCUIT..........................................................................................................648 ELECTRICAL PARKING BRAKE CONTROL........................................................................................................654 PARKING BRAKE VALVE.................................................................................................................656 PARKING SAFETY RELAY................................................................................................................656 NEUTRALIZER RELAY...................................................................................................................656 EMERGENCY BRAKE SWITCH..............................................................................................................656 CONDITIONS..........................................................................................................................657 1. STARTING SWITCH OFF..........................................................................................................657 2. STARTING SWITCH ON...........................................................................................................658 2-1. When parking brake switch is turned ON before starting switch is turned ON.............................................658 2-2. Parking brake switch turned OFF (released) before starting switch is turned ON.........................................659 3. PARKING BRAKE SWITCH TURNED OFF (Released) AFTER STARTING SWITCH IS TURNED ON................................................660 4. PARKING BRAKE SWITCH ON (operated)...........................................................................................661 5. WHEN AIR PRESSURE DROPS......................................................................................................662 BUCKET POSITIONER AND BOOM KICK-OUT.....................................................................................................663 Bucket positioner...................................................................................................................664 Boom kick-out.......................................................................................................................664 PROXIMITY SWITCH........................................................................................................................665 OPERATION...........................................................................................................................665 Lift arm RAISE..................................................................................................................665 Kick-out........................................................................................................................667 BUCKET "TILT".......................................................................................................................668 Hold............................................................................................................................668 Tilt............................................................................................................................669 Positioned......................................................................................................................670 AIR GAUGE CIRCUIT DIAGRAM...............................................................................................................671 ELECTRONIC VEHICLE MONITORING SYSTEM (RIMS).............................................................................................672 INDICATION ON MONITOR PANEL.........................................................................................................674 MONITOR WIRING HARNESS..............................................................................................................677 SENSORS.................................................................................................................................678 ENGINE OIL LEVEL....................................................................................................................678 BRAKE OIL LEVEL.....................................................................................................................679 COOLANT LEVEL.......................................................................................................................679 FUEL GAUGE..........................................................................................................................680 ENGINE OIL PRESSURE.................................................................................................................681 PARKING BRAKE.......................................................................................................................682 AIR PRESSURE........................................................................................................................683 TORQUE CONVERTER OILTEMPERATURE.....................................................................................................684 COOLANT TEMPERATURE.................................................................................................................684 ROTATIONAL SPEED....................................................................................................................685 BRAKE LINE FAILURE..................................................................................................................685 TRANSMISSION OIL FILTER CLOGGING....................................................................................................686 82 TESTING AND ADJUSTING....................................................................................................................688 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM..............................................................................................691 MACHINE MONITOR (SPEEDOMETER MODULE)....................................................................................................694 TROUBLESHOOTING.........................................................................................................................696 CHECKS BEFORE TROUBLESHOOTING.......................................................................................................697 JUDGMENT ON POWER TRAIN.............................................................................................................698 METHOD OF READING TROUBLESHOOTING TABLE.............................................................................................699 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART...................................................................................699 PRECAUTION WHEN HANDLING CONNECTOR..................................................................................................701 CONNECTOR TERMINAL NUMBERS..........................................................................................................703 ELECTRICAL WIRING DIAGRAM...........................................................................................................709 ELECTRICAL CONNECTOR (CN) DIAGRAM...................................................................................................709 VEHICLE MONITOR SYSTEM DIAGRAM......................................................................................................709 ELECTRICAL CIRCUIT SYSTEM...........................................................................................................710 ENGINE STARTING AND STOP CIRCUIT SYSTEM.........................................................................................710 PARKING BRAKE SYSTEM............................................................................................................711 KICK-DOWN CIRCUIT SYSTEM........................................................................................................712 ETHER INJECTION CIRCUIT SYSTEM..................................................................................................713 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM...............................................................................................714 POSITION OF CONNECTORS FOR TROUBLESHOOTING..........................................................................................715 E-1 ENGINE DOES NOT START...........................................................................................................723 E-2 ENGINE DOES NOT STOP............................................................................................................725 E-3 ENGINE STOPS WHEN TRAVELING.....................................................................................................726 E-4 PARKING BRAKE DOES NOT WORK.....................................................................................................727 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING.........................................................................................729 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.....................................................................731 E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL, (PARKING BRAKE IS WORKING NORMALLY.).........................731 E-8 TRANSMISSION DOES NOT WORK NORMALLY.............................................................................................733 E-9 KICK-DOWN SWITCH DOES NOT WORK..................................................................................................755 E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)...............758 E-11 KICK-DOWN OPERATION IS NOT CANCELED............................................................................................759 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2................................................................................761 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.......................................................................761 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM..........................................................................764 POSITION OF CONNECTORS FOR TROUBLESHOOTING..........................................................................................765 M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED................................................................................776 M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED...............................................................................777 M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED...........................................................................778 M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING.................................................................................778 M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING...............................................................780 M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING.....................................................................................781 M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING.............................................................................781 M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING............................................................................783 M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING...........................................................................783 M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING..........................................................................785 M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING......................................................................785 M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING..............................................................785 M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP......................................................................787 M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP......................................................................789 M-15 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP............................................................................791 M-16 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT...............................................................................793 M-17 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON................................................................798 M-18 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.....................................................................................799 M-19 HOURMETER DISPLAY DOES NOT WORK NORMALLY.......................................................................................800 M-20 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS.............................................801 M-21 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT........................................802 M-22 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED...............................................803 M-23 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP.........................................805 M-24 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC. WITH .........811 M-25 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS....................................................811 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.......813 M-27 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP.................................................814 M-28 ABNORMALITY IN THE FUEL GAUGE SYSTEM...........................................................................................815 M-29 ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM...................................................................................817 M-30 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM.......................................................................819 M-31 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM...............................................................821 83 DISASSEMBLY AND ASSEMBLY.................................................................................................................824 MACHINE MONITOR.........................................................................................................................825 REMOVAL.............................................................................................................................825 INSTALLATION........................................................................................................................826 90 OTHERS.......................................................................................................................................828 91 AIR CONDITIONER STRUCTURE AND FUNCTION...................................................................................................828 GENERAL.................................................................................................................................830 BASIC INFORMATION ON AIR CONDITIONERS...............................................................................................830 UNITS RELATED TO REFRIGERATION..................................................................................................830 Heat........................................................................................................................830 Temperature.................................................................................................................830 Pressure....................................................................................................................831 Humidity....................................................................................................................832 PRINCIPLE OF COOLING............................................................................................................833 Why do coolers cool?........................................................................................................833 Refrigerator using evaporation latent heat..................................................................................833 Refrigeration method (Vapor compression)....................................................................................833 Refrigerating cycle.........................................................................................................834 Heating cycle...............................................................................................................836 REFRIGERANTS....................................................................................................................837 SAFETY PRECAUTIONS..........................................................................................................837 REFRIGERATOR OIL (LUBE OIL).....................................................................................................838 SPECIFICATIONS..................................................................................................................839 PIPING DIAGRAM..........................................................................................................................840 ELECTRIC WIRING DIAGRAM.................................................................................................................841 COMPRESSOR (CRANK TYPE).................................................................................................................842 MAGNETIC CLUTCH.........................................................................................................................845 CONDENSER...............................................................................................................................846 RECEIVER W/SIGHT GLASS..................................................................................................................848 AIR CONDITIONER UNIT....................................................................................................................850 EXPANSION VALVE.....................................................................................................................851 EVAPORATOR..........................................................................................................................853 THERMOSTAT..........................................................................................................................853 PRESSURE SWITCH.....................................................................................................................854 HEATER..............................................................................................................................856 BLOWER UNIT.........................................................................................................................856 PIPING..............................................................................................................................857 AIR CONTROL SYSTEM..................................................................................................................858 CONTROL PANEL...........................................................................................................................859 BLOWER SWITCH.......................................................................................................................859 AIR CONDITIONER SWITCH..............................................................................................................859 TEMPERATURE CONTROL LEVER...........................................................................................................859 AIR SOURCE SELECTOR LEVER...........................................................................................................859 92 AIR CONDITIONER TESTING AND ADJUSTING....................................................................................................860 SERVICE TOOLS...........................................................................................................................862 GAUGE MANIFOLD......................................................................................................................862 GAS LEAK DETECTOR...................................................................................................................865 HALIDE TORCH LEAK DETECTOR......................................................................................................865 ELECTRIC LEAK TESTER............................................................................................................867 VALVE FOR SERVICE CANS..............................................................................................................868 MAINTENANCE PROCEDURE...................................................................................................................869 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING......................................................................................869 PROHIBITED WORK.................................................................................................................869 OTHER PRECAUTIONS...............................................................................................................869 BLEEDING AIR FROM REFRIGERATION CIRCUIT.............................................................................................871 PURPOSE.........................................................................................................................871 CONNECTING GAUGE MANIFOLD.......................................................................................................871 EVACUATION......................................................................................................................872 AIR-TIGHTNESS CHECK.............................................................................................................872 GAS-LEAK CHECK..................................................................................................................872 EVACUATION (REPEATING)..........................................................................................................873 CHARGINGTHE REFRIGERATION CIRCUIT WITH REFRIGERANT..................................................................................874 CHARGING FROM THE HIGH-PRESSURE SIDE............................................................................................874 CHARGING FROM THE LOW PRESSURE SIDE (REPLENISHINGTHEREFRIGERATIONCIRCUIT).......................................................875 WHEN THE AMBIENT TEMPERATURE IS LOW.............................................................................................876 WHEN THE AMBIENT TEMPERATURE IS HIGH............................................................................................876 REPLACING SERVICE CANS..............................................................................................................877 CHECKING THE AMOUNT OF REFRIGERANT..................................................................................................877 REMOVAL OF GAUGE MANIFOLD...........................................................................................................879 DISCHARGING THE REFRIGERANT.........................................................................................................879 DAILY CHECKS........................................................................................................................880 CHECK REFRIGERANT LEVEL.........................................................................................................880 CLEANING THE CONDENSER..........................................................................................................880 CHECKING THE V-BELT.............................................................................................................880 CHECKING OIL LEVEL..................................................................................................................881 PROCEDURE FOR CHECKING..........................................................................................................881 PROCEDURE FOR CHECKING OIL LEVEL................................................................................................881 ADDING AND REMOVING OIL.........................................................................................................882 ADDING OIL BY EVACUATION........................................................................................................882 TROUBLESHOOTING.........................................................................................................................883 VISUAL AND ACOUSTICAL CHECKS........................................................................................................883 DEFECTIVE COOLING...................................................................................................................884 TROUBLESHOOTING TABLES..............................................................................................................885 DEFECTIVE HEATING...................................................................................................................887 TROUBLESHOOTING USING GAUGE MANIFOLD....................................................................................................888 PREPARATIONS BEFORE MEASURING.......................................................................................................888 INSUFFICIENT REFRIGERANT............................................................................................................888 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER..........................................................................889 AIR INSIDE REFRIGERATION SYSTEM.....................................................................................................889 MOISTURE IN REFRIGERATING SYSTEM....................................................................................................890 REFRIGERANT DOES NOT CIRCULATE......................................................................................................891 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE...................................................892 DEFECTIVE MOUNTING OF HEAT SENSING TUBE.............................................................................................892 DEFECTIVE COMPRESSION BY COMPRESSOR.................................................................................................892 93 AIR CONDITIONER DISASSEMBLY AND ASSEMBLY.................................................................................................894 SPECIAL TOOLS...........................................................................................................................895 MAGNETIC CLUTCH.........................................................................................................................896 DISASSEMBLY OF......................................................................................................................896 CHECKS BEFORE DISASSEMBLY.......................................................................................................897 REMOVAL OF ROTOR AND STATOR.....................................................................................................897 REMOVAL OF CENTER PIECE FROM ROTOR..............................................................................................898 REMOVAL OF BEARING FROM ROTOR...................................................................................................899 ASSEMBLY OF.........................................................................................................................900 ASSEMBLY OF BEARING TO ROTOR....................................................................................................900 ASSEMBLY OF CENTER PIECE TO ROTOR...............................................................................................900 ASSEMBLY OF STATOR AND ROTOR TO COMPRESSOR......................................................................................901 AIR CONDITIONER UNIT....................................................................................................................902 DISASSEMBLY OF......................................................................................................................902 CHECKS BEFORE DISASSEMBLY.......................................................................................................902 REMOVAL OF CONTROL PANEL AND THERMOSTAT.........................................................................................906 REMOVAL OF UNIT COVER...........................................................................................................908 REMOVAL OF WATER VALVE..........................................................................................................908 REMOVAL OF EXPANSION VALVE......................................................................................................910 REMOVAL OF EVAPORATOR...........................................................................................................912 REMOVAL OF HEATER CORE..........................................................................................................912 REMOVAL OF PRESSURE SWITCHES....................................................................................................912 BLOWER UNIT.............................................................................................................................913 DISASSEMBLY OF......................................................................................................................913 CHECKS BEFORE DISASSEMBLY.......................................................................................................913 REMOVAL OF BLOWER RESISTOR......................................................................................................913 REMOVAL OF BLOWER MOTOR AND FAN.................................................................................................914 CONDENSER...............................................................................................................................915 DISASSEMBLY OF......................................................................................................................915 CHECKS BEFORE DISASSEMBLY.......................................................................................................915 REMOVAL OF CONDENSER, FAN MOTOR.................................................................................................916 REMOVAL OF PRESSURE SWITCH......................................................................................................917 REMOVAL OF RESISTOR.............................................................................................................917 97 GEAR PUMP SA SERIES......................................................................................................................918 GENERAL.................................................................................................................................919 PRINCIPLE OF OPERATION..............................................................................................................920 PRESSURE LOADED TYPE GEAR PUMP......................................................................................................923 FIXED SIDE PLATE TYPE GEAR PUMP.....................................................................................................925 SA SERIES...............................................................................................................................926 STRUCTURE...........................................................................................................................926 TESTING AND ADJUSTING...............................................................................................................930 DISASSEMBLY.........................................................................................................................933 ASSEMBLY............................................................................................................................937 MAINTENANCE STANDARD................................................................................................................942 99 METRIC CONVERSIONS.......................................................................................................................944 METRIC CONVERSIONS......................................................................................................................945
KOMATSU WA500-1LC WHEEL LOADER SHOP MANUAL CEBMW25050 – PDF DOWNLOAD:
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