Komatsu WA500-1 Wheel Loader Shop Manual SEBM0425M102

Description

• Model List:
  • WA500-1 Wheel Loader

• 1. COVER
• 2. CONTENTS
• 3. STRUCTURE AND FUNCTION
• 3.1. GENERAL
• 3.2. RADIATOR AND OIL COOLER
• 3.3. DAMPER
• 3.4. TORQUE CONVERTER AND TRANSMISSION PIPING
• 3.5. HYDRAULIC CIRCUIT FOR POWER TRAIN
• 3.6. HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
• 3.7. TORQUE CONVERTER AND PTO
• 3.8. TRANSMISSION
• 3.9. TRANSMISSION CONTROL VALVE
• 3.10. TRANSMISSION SOLENOID VALVE
• 3.11. TORQUE CONVERTER OIL FILTER
• 3.12. PILOT OIL FILTER
• 3.13. CENTER HINGE PIN
• 3.14. STEERING PIPING
• 3.15. STEERING CIRCUIT DIAGRAM
• 3.16. STEERING COLUMN AND GEAR BOX
• 3.17. STEERING LINKAGE
• 3.18. STEERING VALVE
• 3.19. BRAKE AND AIR PIPING
• 3.20. BRAKE AND AIR CIRCUIT DIAGRAM
• 3.21. BRAKE AND AIR CIRCUIT SYSTEM
• 3.22. PARKING BRAKE SOLENOID VALVE
• 3.23. SPRING CYLINDER
• 3.24. BRAKE
• 3.25. PARKING BRAKE
• 3.26. BRAKE CALIPER
• 3.27. HYDRAULIC PIPING
• 3.28. HYDRAULIC CIRCUIT SYSTEM
• 3.29. HYDRAULIC CIRCUIT DIAGRAM
• 3.30. WORK EQUIPMENT LEVER LINKAGE
• 3.31. HYDRAULIC TANK
• 3.32. ACCUMULATOR
• 3.33. PPC VALVE
• 3.34. PPC RELIEF VALVE
• 3.35. MAIN CONTROL VALVE
• 3.36. OPERATION OF MAIN CONTROL VALVE
• 3.37. BUCKET LINKAGE
• 3.38. BUCKET
• 3.39. BUCKET POSITIONER AND BOOM KICKOUT
• 3.40. OPERATION OF PROXIMITY SWITCH
• 3.42. AIR CONDITIONER
• 3.43. ELECTRICAL WIRING DIAGRAM CIRCUIT
• 3.44. ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER
• 3.45. ELECTRICAL CIRCUIT DIAGRAM FOR AIR GAUGE
• 3.46. ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
• 3.47. ENGINE STARTING CIRCUIT
• 3.48. ENGINE STOP CIRCUIT
• 3.49. PREHEATING CIRCUIT
• 3.50. COMBINATION SWITCH
• 3.51. ELECTRICAL TRANSMISSION CONTROL
• 3.52. KICKDOWN SWITCH
• 3.53. ELECTRICAL PARKING BRAKE CONTROL
• 4. TESTING AND ADJUSTING
• 4.1. STANDARD VALUE TABLE FOR ENGINE
• 4.2. STANDARD VALUE TABLE FOR CHASSIS
• 4.3. STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
• 4.4. TOOL LIST FOR TESTING AND ADJUSTING
• 4.5. ADJUSTING VALVE CLEARANCE
• 4.6. MEASURING COMPRESSION PRESSURE
• 4.7. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 4.8. MEASURING EXHAUST GAS COLOR
• 4.9. MEASURING BLOWBY PRESSURE
• 4.10. MEASURING ENGINE OIL PRESSURE AND TEMPERATURE
• 4.11. TESTING AND ADJUSTING BELT TENSION
• 4.12. MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE
• 4.13. MEASURING SHIFT LEVER
• 4.14. MEASURING ENGINE STALL SPEED
• 4.15. MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION
• 4.16. METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
• 4.17. TIRE AND WHEEL
• 4.18. MEASURING STEERING WHEEL PLAY
• 4.19. MEASURING OPERATING FORCE OF STEERING WHEEL
• 4.20. OPERATING TIME OF STEERING WHEEL
• 4.21. TESTING AND ADJUSTING STEERING LINKAGE
• 4.22. STEERING OIL PRESSURE
• 4.23. MEASURING BRAKE PEDAL
• 4.24. MEASURING AIR PRESSURE
• 4.25. BRAKE PERFORMANCE
• 4.26. CHECKING BRAKE PISTON LEAKAGE
• 4.27. MEASURING WEAR OF BRAKE DISC
• 4.28. AIR BLEEDING FROM BRAKE LINE
• 4.29. PARKING BRAKE PERFORMANCE
• 4.30. CHECKING AND ADJUSTING PARKING BRAKE
• 4.31. MEASURING DUMP AND LIFT CONTROL LEVERS
• 4.32. MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT
• 4.33. MEASURING WORK EQUIPMENT
• 4.34. MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT
• 4.35. ADJUSTING BUCKET POSITIONER
• 4.36. ADJUSTING BOOM KICKOUT
• 4.37. ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR
• 4.38. TROUBLESHOOTING
• 4.38.1. ELECTRICAL CIRCUIT DIAGRAM
• 4.38.2. ELECTRICAL WIRING DIAGRAM
• 4.38.3. CONNECTOR TERMINAL NUMBERS
• 4.38.4. PRECAUTION WHEN HANDLING CONNECTOR
• 4.38.5. TROUBLESHOOTING PROCEDURE
• 4.38.6. CHECK BEFORE TROUBLESHOOTING
• 4.38.7. JUDGEMENT ON POWER TRAIN
• 4.38.8. METHOD OF USING YESNO TROUBLESHOOTING FLOW CHART
• 4.38.9. METHOD OF READING TROUBLESHOOTING TABLE
• 4.38.10. TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM
• 4.38.11. TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM
• 4.38.12. TROUBLESHOOTING TABLE FOR HYDRAULIC AND MECHANICAL SYSTEM
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. FUEL INJECTION PUMP
• 5.2. TORQUE CONVERTER CHARGING PUMP
• 5.2.1. REMOVAL
• 5.2.2. INSTALLATION
• 5.3. TORQUE CONVERTER AND TRANSMISSION
• 5.3.1. REMOVAL
• 5.3.2. INSTALLATION
• 5.4. TORQUE CONVERTER
• 5.5. TRANSMISSION CONTROL VALVE
• 5.6. MAIN RELIEF VALVE
• 5.6.1. DISASSEMBLY (SERIAL NO.2000120033)
• 5.6.2. ASSEMBLY (SERIAL NO.2000120033)
• 5.6.3. DISASSEMBLY (SERIAL NO.20034 AND UP)
• 5.6.4. ASSEMBLY (SERIAL NO.20034 AND UP)
• 5.7. FRONT AXLE
• 5.7.1. REMOVAL
• 5.7.2. INSTALLATION
• 5.8. FRONT DIFFERENTIAL
• 5.9. REAR DIFFERENTIAL
• 5.9.1. REMOVAL
• 5.9.2. INSTALLATION
• 5.10. DIFFERENTIAL GEAR
• 5.11. STEERING GEAR BOX
• 5.11.1. DISASSEMBLY
• 5.11.2. ASSEMBLY
• 5.12. STEERING PUMP AND PPC PUMP
• 5.13. STEERING CYLINDER
• 5.14. BRAKE(FRONT,REAR)
• 5.14.1. DISASSEMBLY
• 5.14.2. ASSEMBLY
• 5.15. SPRING CYLINDER
• 5.16. PARKING BRAKE PAD
• 5.17. HYDRAULIC FILTER
• 5.18. PPC RELIEF VALVE
• 5.18.1. DISASSEMBLY
• 5.18.2. ASSEMBLY
• 5.19. MAIN CONTROL VALVE
• 5.20. LIFT AND DUMP CYLINDERS
• 5.20.1. DISASSEMBLY
• 5.20.2. ASSEMBLY
• 5.21. CENTER HINGE PIN
• 5.22. AIR CONDITIONER UNIT
• 5.22.1. REMOVAL
• 5.22.2. INSTALLATION
• 5.23. AIR CONDITIONER CONDENSER
• 5.24. COMPRESSOR FOR AIR CONDITIONER
• 5.24.1. REMOVAL
• 5.24.2. INSTALLATION
• 5.25. MACHINE MONITOR
• 5.25.1. REMOVAL
• 5.25.2. INSTALLATION
• 6. MAINTENANCE STANDARD
• 6.1. ENGINE MOUNT
• 6.2. TRANSMISSION MOUNT
• 6.3. DAMPER
• 6.4. TORQUE CONVERTER CHARGING PUMP
• 6.5. TORQUE CONVERTER AND PTO
• 6.6. TRANSMISSION
• 6.7. TRANSFER
• 6.8. TRANSMISSION CONTROL VALVE
• 6.9. CENTER HINGE PIN
• 6.10. STEERING LINKAGE AND STEERING COLUMN
• 6.11. STEERING GEAR BOX
• 6.12. STEERING PUMP
• 6.13. STEERING VALVE
• 6.14. STEERING CYLINDER MOUNT
• 6.15. SPRING CYLINDER
• 6.16. HYDRAULIC AND SWITCH PUMP
• 6.17. PPC PUMP
• 6.18. PPC VALVE
• 6.19. MAIN CONTROL VALVE
• 6.20. HYDRAULIC CYLINDERS
• 6.21. BUCKET LINKAGE
• 6.22. BUCKET
• 6.23. BUCKET POSITIONER AND BOOM KICKOUT