Komatsu WA500-1 Wheel Loader Service Repair Shop Manual (20001 and up) - SEBM0425M102

This Complete Service Repair Workshop Manual PDF Download for the WA500-1 Komatsu Wheel Loader (SN: 20001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu WA500-1 Wheel Loader
Serial Numbers : 20001 and up


TABLE OF CONTENTS :

10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEBM0425M102
Total Pages : 792


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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COVER
CONTENTS

10 STRUCTURE AND FUNCTION
GENERAL
RADIATOR AND OIL COOLER
DAMPER
TORQUE CONVERTER AND TRANSMISSION PIPING
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
TORQUE CONVERTER AND PTO
TRANSMISSION
TRANSMISSION CONTROL VALVE
TRANSMISSION SOLENOID VALVE
TORQUE CONVERTER OIL FILTER
PILOT OIL FILTER
TRANSFER
DRIVE SHAFT
CENTER SUPPORT
AXLE
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
TIRE AND WHEEL
CENTER HINGE PIN
STEERING PIPING
STEERING CIRCUIT DIAGRAM
STEERING COLUMN AND GEAR BOX
STEERING LINKAGE
STEERING VALVE
BRAKE AND AIR PIPING
BRAKE AND AIR CIRCUIT DIAGRAM
BRAKE AND AIR CIRCUIT SYSTEM
AIR GOVERNOR
AIR TANK
SAFETY VALVE
BRAKE VALVE
TWO-WAY VALVE
BRAKE CHAMBER
SLACK ADJUSTER
CHECK VALVE
PARKING BRAKE SOLENOID VALVE
SPRING CYLINDER
BRAKE
PARKING BRAKE
BRAKE CALIPER
HYDRAULIC PIPING
HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
HYDRAULIC TANK
ACCUMULATOR
PPC VALVE
PPC RELIEF VALVE
MAIN CONTROL VALVE
OPERATION OF MAIN CONTROL VALVE
BUCKET LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
OPERATION OF PROXIMITY SWITCH
CAB
AIR CONDITIONER
ELECTRICAL WIRING DIAGRAM CIRCUIT
ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER
ELECTRICAL CIRCUIT DIAGRAM FOR AIR GAUGE
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
PREHEATING CIRCUIT
COMBINATION SWITCH
ELECTRICAL TRANSMISSION CONTROL
KICK-DOWN SWITCH
ELECTRICAL PARKING BRAKE CONTROL

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
TOOL LIST FOR TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING EXHAUST GAS COLOR
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE
TESTING AND ADJUSTING BELT TENSION
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE
MEASURING SHIFT LEVER
MEASURING ENGINE STALL SPEED
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
TIRE AND WHEEL
MEASURING STEERING WHEEL PLAY
MEASURING OPERATING FORCE OF STEERING WHEEL
OPERATING TIME OF STEERING WHEEL
TESTING AND ADJUSTING STEERING LINKAGE
STEERING OIL PRESSURE
MEASURING BRAKE PEDAL
MEASURING AIR PRESSURE
BRAKE PERFORMANCE
CHECKING BRAKE PISTON LEAKAGE
MEASURING WEAR OF BRAKE DISC
AIR BLEEDING FROM BRAKE LINE
PARKING BRAKE PERFORMANCE
CHECKING AND ADJUSTING PARKING BRAKE
MEASURING DUMP AND LIFT CONTROL LEVERS
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT
MEASURING WORK EQUIPMENT
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT
ADJUSTING BUCKET POSITIONER
ADJUSTING BOOM KICK-OUT
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL WIRING DIAGRAM
CONNECTOR TERMINAL NUMBERS
PRECAUTION WHEN HANDLING CONNECTOR
TROUBLESHOOTING PROCEDURE
CHECK BEFORE TROUBLESHOOTING
JUDGEMENT ON POWER TRAIN
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART
METHOD OF READING TROUBLESHOOTING TABLE
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM
POSITION OF CONNECTORS FOR TROUBLESHOOTING
E-1. ENGINE DOES NOT START
E-2. ENGINE DOES NOT STOP
E-3. ENGINE STOPS WHEN TRAVELING
E-4. PARKING BRAKE DOES NOT WORK
E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING
E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON
E-7. WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL (PARKING BRAKE IS WORKING NORMALLY)
E-8. TRANSMISSION DOES NOT WORK NORMALLY
E-9. KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1-F4 SWITCHES CORRECTLY)
E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)
E-11. KICK-DOWN OPERATION IS NOT CANCELED
E-12. KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2
E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED
E-14. PREHEAT DISPLAY STAYS ON
E-15. PREHEATING DOES NOT STOP
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM
CONNECTOR TYPES AND LOCATION OF COMPONENTS
M-1. (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED
M-2. (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED
M-3. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED
M-4. (BATTERY CHARGE ) FLASHES WHEN ENGINE IS RUNNING
M-5. (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING
M-6. (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING
M-7. (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING
M-8. (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING
M-9. (RADIATOR WATER LEVER) FLASHES WHEN ENGINE IS RUNNING
M-10. (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING
M-11. (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING
M-12. (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING
M-13. (PARKING BRAKE) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP
a) IF STAYS LIGHTED UP
b) IF DOES NOT LIGHT UP
M-14. (WORKING LAMP) LIGHTS UP ABNORMALLY,OR DOES NOT LIGHT UP
a) IF STAYS LIGHTED UP
b) IF DOES NOT LIGHT UP
M-15. (PREHEATING ) LIGHTS UP,OR DOES NOT LIGHT UP
a) (PREHEATING) LIGHTS UP
b) (PREHEATING) DOES NOT LIGHT UP
M-16. (TRANSMISSION CUT-OFF) LIGHTS UP, OR DOES NOT LIGHT UP
a) LIGHTS UP
b) DOES NOT LIGHT UP
M-17. TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP
a) TURN SIGNAL (RIGHT) PILOT DISPLAY LIGHTS UP
b) TURN SIGNAL (LEFT) PILOT DISPLAY LIGHTS UP
c) TURN SIGNAL (RIGHT) PILOT DISPLAY DOES NOT LIGHT UP
d) TURN SIGNAL (LEFT) PILOT DISPLAY DOES NOT LIGHT UP
e) HI BEAM PILOT DOES NOT LIGHT UP
f) HI BEAM PILOT STAYS LIGHTED UP
M-18. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON
M-19. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY
M-20. HOURMETER DOES NOT WORK NORMALLY
M-21. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS
a) NONE OF MONITOR PANEL LIGHTS UP
b) EXCEPT FOR SPEEDOMETER MODULE, NONE OF MONITOR PANEL LIGHTS UP
c) NONE OF CAUTION ITEMS LIGHT UP
d) SOME OTHER PARTS DO NOT LIGHT UP
M-22. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP,BUT DOES NOT GO OUT
M-23. (ENGINE OIL PRESSURE) FLASHES OR (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED
a) (ENGINE OIL PRESSURE) FLASHES, AND ALARM BUZZER AND WARNING LAMP ARE ACTUATED
b) (BATTERY CHARGE)FLASHES, AND WARNING LAMP LIGHTS UP
M-24. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP,OR PART DOES NOT LIGHT UP
a) EVEN WHEN COMBINATION LAMP IS PLACED AT SMALL, NONE OF PANEL LIGHTING LIGHTS UP
b) EVEN WHEN WORKING LAMP IS SWITCHED ON, NONE OF MONITOR PANEL LIGHTS UP
c) EVEN WHEN STARTING SWITCH IS TURNED ON,NONE OF MONITOR PANEL LIGHTS UP
d) PART OF PANEL DOES NOT LIGHT UP
M-25. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC.CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND
M-26. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS
M-27. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC.CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH
M-28. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP
M-29. ABNORMALITY IN (FUEL GAUGE) SYSTEM
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA
b) IF INDICATOR REMAINS AT FULL
M-30. ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA
b) IF INDICATOR REMAINS AT MAXIMUM LEVEL
M-31. ABNORMALITY IN (ENGINE WATER TEMPERATURE GAUGE) SYSTEM
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA
b) IF INDICATOR REMAINS AT MINIMUM LEVEL
M-32. ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA
b) IF INDICATOR REMAINS AT MINIMUM LEVEL
TROUBLESHOOTING TABLE FOR HYDRAULIC AND MECHANICAL SYSTEM
TROUBLESHOOTING TABLE
TORQUE CONVERTER AND TRANSMISSION
T-1.MACHINE DOES NOT MOVE
T-2.MACHINE LACKS POWER OR SPEED
T-3.EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR
T-4.TORQUE CONVERTER OIL TEMPERATURE TOO HIGH
STEERING SYSTEM
S-1. STEERING WHEEL DOES NOT TURN
S-2. STEERING WHEEL IS SLUGGISH
S-3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK
S-4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING
S-5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT
AIR AND BRAKE SYSTEM
A-1. AIR PRESSURE DOES NOT RISE AT ALL
A-2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE
A-3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE
A-4. BRAKE DOES NOT RELEASE, OR DRAGS
A-5. PARKING BRAKE DOES NOT RELEASE, OR DRAGS (APPLIES TO MACHINE EQUIPPED WITH AIR PARKING BRAKE)
WORK EQUIPMENT
H-1. LIFT ARM DOES NOT RISE
H-2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER
H-3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT
H-4. BUCKET CANNOT BE HELD DOWN WITH LIFT ARM CYLINDER
H-5. LIFT ARM HAS LARGE HYDRAULIC DRIFT
H-6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK
H-7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD"TO "RAISE"
H-8. BUCKET DOES NOT TILT BACK
H-9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER
H-10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK
H-11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER
H-12. BUCKET HAS LARGE HYDRAULIC DRIFT
H-13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD. (MAIN CONTROL VALVE IN "HOLD")
H-14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"
H-15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY

30 DISASSEMBLY AND ASSEMBLY
STARTING MOTOR
REMOVAL
INSTALLATION
ALTERNATOR
REMOVAL
INSTALLATION
OIL COOLER
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
TURBOCHARGER
REMOVAL
INSTALLATION
AIR COMPRESSOR
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
DAMPER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER CHARGING PUMP
REMOVAL
INSTALLATION
TORQUE CONVERTER AND TRANSMISSION
REMOVAL
INSTALLATION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
ASSEMBLY
TRANSFER
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
LOWER VALVE
DISASSEMBLY
ASSEMBLY
UPPER VALVE
DISASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
DISASSEMBLY
ASSEMBLY
CENTER SUPPORT
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
DRIVE SHAFT
DISASSEMBLY (SERIAL NO.20001-20033)
ASSEMBLY (SERIAL NO.20001-20033)
DISASSEMBLY (SERIAL NO.20034 AND UP)
ASSEMBLY (SERIAL NO.20034 AND UP)
FRONT AXLE
REMOVAL
INSTALLATION
FRONT DIFFERENTIAL
REMOVAL
INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
REAR DIFFERENTIAL
REMOVAL
INSTALLATION
DIFFERENTIAL GEAR
DISASSEMBLY
ASSEMBLY
FINAL DRIVE
DISASSEMBLY
ASSEMBLY
STEERING GEAR
REMOVAL
INSTALLATION
STEERING GEAR BOX
DISASSEMBLY
ASSEMBLY
STEERING PUMP AND PPC PUMP
REMOVAL
INSTALLATION
STEERING VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
AIR GOVERNOR
DISASSEMBLY
ASSEMBLY
BRAKE VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BRAKE CHAMBER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SLACK ADJUSTER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BRAKE
REMOVAL
INSTALLATION
BRAKE(FRONT,REAR)
DISASSEMBLY
ASSEMBLY
SPRING CYLINDER
REMOVAL
INSTALLATION
PARKING BRAKE
REMOVAL
INSTALLATION
PARKING BRAKE PAD
REMOVAL
INSTALLATION
HYDRAULIC TANK
REMOVAL
INSTALLATION
HYDRAULIC FILTER
REMOVAL
INSTALLATION
HYDRAULIC PUMP
REMOVAL
INSTALLATION
SWITCH PUMP
REMOVAL
INSTALLATION
PPC VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PPC RELIEF VALVE
DISASSEMBLY
ASSEMBLY
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
DUMP CYLINDER
REMOVAL
INSTALLATION
LIFT CYLINDER
REMOVAL
INSTALLATION
LIFT AND DUMP CYLINDERS
DISASSEMBLY
ASSEMBLY
CENTER HINGE PIN
REMOVAL
INSTALLATION
WORK EQUIPMENT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
CAB
REMOVAL
INSTALLATION
AIR CONDITIONER UNIT
REMOVAL
INSTALLATION
AIR CONDITIONER CONDENSER
REMOVAL
INSTALLATION
DRY RESERVOIR
REMOVAL
INSTALLATION
COMPRESSOR FOR AIR CONDITIONER
REMOVAL
INSTALLATION
MACHINE MONITOR
REMOVAL
INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT
TRANSMISSION MOUNT
DAMPER
TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER AND PTO
TRANSMISSION
TRANSFER
TRANSMISSION CONTROL VALVE
CENTER SUPPORT
DRIVE SHAFT
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
STEERING LINKAGE AND STEERING COLUMN
STEERING GEAR BOX
STEERING PUMP
STEERING VALVE
STEERING CYLINDER MOUNT
BRAKE VALVE
BRAKE CHAMBER
SLACK ADJUSTER
BRAKE
PARKING BRAKE
SPRING CYLINDER
HYDRAULIC AND SWITCH PUMP
PPC PUMP
PPC VALVE
MAIN CONTROL VALVE
HYDRAULIC CYLINDERS
BUCKET LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT

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