Komatsu WA500-1 WA500-3 WA500-6 WA500-7 WA500-8 Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA500.zip
A full-service repair guide—complete with Electrical Wiring Diagrams—covering the Komatsu WA500 Wheel Loader, packed with every technical detail needed to service, troubleshoot, and rebuild the machine the way a professional technician would.
The Komatsu WA500 Wheel Loader workshop service repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 35,532 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
00 Index and foreword ...3
Index ...4
Foreword, safety and general information ...21
Important safety notice ...21
How to read the shop manual ...28
Explanation of terms for maintenance standard ...30
Handling equipment of fuel system devices ...32
Handling of intake system parts ...33
Handling of hydraulic equipment ...34
Method of disconnecting and connecting of push-pull type coupler ...36
Handling of electrical equipment ...39
How to read electric wire code ...47
Precautions when performing operation ...50
Practical use of KOMTRAX ...54
Standard tightening torque table ...55
List of abbreviation ...59
Conversion table ...64
01 Specification ...69
Table of contents ...70
Specifications ...71
Specification drawing ...71
Specification ...73
Weight table ...80
Table of fuel, coolant, and lubricants ...82
10 Structure and function ...85
Table of contents ...86
Engine and cooling system ...88
Engine related parts ...88
KVGT ...90
EGR system piping drawing ...96
EGR system circuit diagram ...98
EGR valve ...99
EGR cooler ...101
KCCV layout drawing ...103
KCCV ventilator ...105
KDPF ...107
Engine mount and transmission mount ...111
Joint ...112
Cooling system ...113
Cooling fan pump ...117
Cooling fan motor ...126
Power train ...133
Power train system ...133
Drive shaft ...136
Power train piping drawing ...137
Transmission control ...138
Torque converter ...140
Torque converter regulator valve ...147
Transmission ...149
Transfer ...166
Transmission control valve ...168
Forward and reverse clutch ECMV and gear speed clutch ECMV ...171
Lockup clutch ECMV ...178
Main relief valve, torque converter relief valve, and main flow selector valve ...182
Torque converter oil cooler ...187
Center support ...188
Lubricating oil relief valve ...189
Axle ...190
Differential ...194
Final drive ...204
Steering system ...206
Layout of steering parts ...206
Steering column ...207
Joystick steering lever linkage ...208
Steering pump ...209
Steering control valve ...221
Orbitrol valve ...231
Stop valve ...237
Emergency steering piping diagram ...238
Diverter valve ...239
Emergency steering pump ...243
Brake system ...244
Layout of brake parts ...244
Charge valve ...246
Brake valve ...252
Slack adjuster ...257
Accumulator (for brake) ...260
Brake ...261
Parking brake control ...263
Parking brake ...264
Parking brake solenoid valve ...266
Parking brake emergency release valve ...269
Undercarriage and frame ...270
Axle mount ...270
Center hinge pin ...271
Tire ...273
Hydraulic system ...275
Hydraulic component layout ...275
Work equipment control ...277
Hydraulic tank ...279
Double type gear pump ...282
Work equipment pump ...283
Control valve ...304
CLSS ...313
Hydraulic circuit diagram and names of valves ...317
Accumulator charge valve ...329
Work equipment lock solenoid valve ...333
Accumulator (for PPC circuit) ...334
Accumulator (for ECSS) ...335
Work equipment ...336
Work equipment linkage ...336
Bucket ...337
Bucket positioner and boom positioner ...339
Lubrication of work equipment ...340
Cab and its attachments ...342
ROPS cab ...342
Electrical system ...343
Engine control system ...343
Preheating system ...345
Power mode selector circuit ...347
Engine output limit function ...348
Automatic warm-up function ...349
Parking brake control system ...350
System operating lamp function ...352
Battery disconnect switch function ...354
Backup lamp and brake lamp ...356
Clearance lamp and headlamp ...358
Working lamp ...359
Horn circuit ...360
Wiper and window washer circuit ...361
Transmission controller system ...364
Work equipment control system ...389
Machine monitor system ...409
Rear view monitor system ...433
KOMTRAX system ...436
System component parts ...439
Sensor ...473
20 Standard value tables ...497
Table of contents ...498
Standard service value table ...499
Standard value table for engine ...499
Standard value table for machine ...501
Standard value table for electrical system ...516
30 Testing and adjusting ...531
Table of contents ...532
General information on testing and adjusting ...534
Tools for testing and adjusting ...534
Sketch of tools for testing and adjusting ...539
Engine and cooling system ...541
Testing engine speed ...541
Testing boost pressure ...543
Testing exhaust gas temperature ...545
Testing exhaust gas color ...547
Testing and adjusting valve clearance ...550
Testing compression pressure ...552
Testing blowby pressure ...555
Testing engine oil pressure ...557
Testing EGR valve and KVGT driving oil pressure ...559
Testing fuel pressure ...561
Testing fuel return rate and leakage ...563
Bleeding air from fuel system ...567
Testing fuel circuit for leakage ...569
Handling cylinder cutout mode operation ...570
Handling no injection cranking operation ...571
Testing of KDPF and muffler stack for looseness and damage ...572
Testing of installed condition of cylinder head and manifolds ...573
Testing engine piping for damage and looseness ...574
Replacing and adjusting belt for alternator and air conditioner compressor ...575
Procedures for cleaning fuel doser ...576
Writing compensation values at replacement of injector and engine controller ...579
Power train ...583
Adjusting transmission output speed sensor ...583
Adjusting transmission input speed sensor ...584
Flushing procedure for torque converter and transmission hydraulic circuit ...585
Retrieval of disabled machine due to transmission valve failure ...587
Testing oil leakage from axle final drive ...589
Testing drive shaft for looseness, backlash, and damage ...590
Testing and adjusting power train oil pressure ...591
Steering system ...605
Testing directional lever ...605
Testing steering wheel ...606
Testing work equipment control lever ...608
Testing and adjusting steering circuit oil pressure ...610
Bleeding air from steering cylinder circuit. ...613
Testing and adjusting steering stopper valve ...614
Brake system ...616
Testing brake pedal ...616
Testing and adjusting brake pedal linkage ...617
Adjustment procedure of transmission cut-off proximity switch of left brake pedal ...618
Testing braking performance ...619
Testing and adjusting of accumulator charge pressure ...620
Testing wheel brake oil pressure ...622
Testing lowering of wheel brake pressure ...623
Testing wear of wheel brake disc ...626
Bleeding air from wheel brake circuit ...627
Releasing remaining pressure in brake accumulator circuit ...629
Testing parking brake performance ...630
Testing parking brake oil pressure ...631
Testing wear of parking brake disc ...633
Method of releasing parking brake manually ...634
Hydraulic system ...636
Testing fan speed ...636
Testing fan pump circuit oil pressure ...637
Bleeding air from hydraulic fan circuit ...639
Testing work equipment EPC oil pressure ...641
Testing and adjusting work equipment oil pressure ...643
Bleeding air from work equipment circuit ...649
Releasing remaining pressure from work equipment circuit ...650
Checking of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...651
Work equipment ...656
Testing and adjusting bucket position detection lever ...656
Testing and adjusting boom position detection lever ...657
Electrical system ...658
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...658
Special functions of machine monitor ...660
Adjusting rearview camera angle ...753
Handling voltage circuit of engine controller ...754
Handling battery disconnect switch ...755
Testing diodes ...756
Pm clinic ...757
Pm Clinic service ...757
Check sheet ...758
40 Troubleshooting ...765
Table of contents ...766
General information on troubleshooting ...776
Troubleshooting points ...776
Sequence of events in troubleshooting ...778
Check before troubleshooting ...780
Inspection procedure before troubleshooting ...782
Preparation work for troubleshooting of electrical system ...799
Classification and procedures for troubleshooting ...805
Symptom and troubleshooting numbers ...808
Information in troubleshooting table ...811
Connector list and layout ...813
Connector contact identification ...828
T-branch box and T-branch adapter table ...864
Fuse location table ...870
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...873
Precautions on troubleshooting of machine monitor ...876
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...878
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...883
Fabrication of short-circuit connector (for CA1883 and CA3135) ...884
Failure codes table ...885
Troubleshooting by failure code (Display of code) ...900
Failure code [1500L0] Double Engagement of T/M Clutches ...900
Failure code [15B0NX] Transmission Oil Filter Clogging ...901
Failure code [15SAL1] Release Trouble of ECMV (Forward) ...902
Failure code [15SALH] Malfunction of ECMV (Forward) ...904
Failure code [15SBL1] Release Trouble of ECMV (Reverse) ...906
Failure code [15SBLH] Malfunction of ECMV (Reverse) ...908
Failure code [15SEL1] Release Trouble of ECMV (1st clutch) ...910
Failure code [15SELH] Malfunction of ECMV (1st) ...912
Failure code [15SFL1] Release Trouble of ECMV (2nd) ...914
Failure code [15SFLH] Malfunction of ECMV (2nd) ...916
Failure code [15SGL1] Release Trouble of ECMV (3rd) ...918
Failure code [15SGLH] Malfunction of ECMV (3rd) ...920
Failure code [15SHL1] Release Trouble of ECMV (4th) ...922
Failure code [15SHLH] Malfunction of ECMV (4th) ...924
Failure code [2F00MA] Failure of Parking Brake Circuit ...926
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...929
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ...931
Failure code [879AKA] A/C Inner Sensor Open Circuit ...933
Failure code [879AKB] A/C Inner Sensor Short Circuit ...934