Komatsu Wheel Loader WA500-3LK Avance Plus service & repair manual

Description Komatsu Wheel Loader WA500-3LK Avance Plus service & repair manual

Komatsu Wheel Loader WA500-3LK Avance Plus pdf workshop service repair manual + operation & maintenance manual

Serial number A71001 and up

MANUAL CONTENT:
GENERAL
DIMENSIONS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
ENGINE OIL
NORMAL OPERATION
ARCTIC OPERATION
TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL
AXLE OIL
GREASE
DIESEL FUEL
COOLANT SPECIFICATIONS
GENERAL
WATER
ANTIFREEZE
SUPPLEMENTAL COOLANT ADDITIVES

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 CUTAWAY
OPERATION OF CLUTCH
FORWARD 1ST
FORWARD 2ND
FORWARD 3RD
FORWARD 4TH
REVERSE 1ST
TRANMISSION CONTROL VALVE
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
OUTLINE OF ECMV
ECMV AND PROPORTIONAL SOLENOID
ECMV AND FILL SWITCH
ACTUATION OF ECMV
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF VALVE
TORQUE CONVERTER RELIEF VALVE
LUBRICATING RELIEF VALVE
TORQUE CONVERTER OIL FILTER
PILOT FILTER
TRANSFER
DRIVE SHAFT
CENTER SUPPORT
AXLE
FRONT
REAR
DIFFERENTIAL
NORMAL - (STANDARD)
LIMITED SLIP (OPTION)
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
TIRE AND WHEEL
STEERING PIPING
STEERING COLUMN
STEERING VALVE
DEMAND VALVE OPERATION
STEERING SPOOL AT NEUTRAL
STEERING SPOOL OPERATED - ENGINE AT LOW / HIGH SPEED
FLOW AMP
FLOW AMP OPERATION
STEERING VALVE OPERATION
STEERING RELIEF VALVE
RELIEF VALVE OPERATION
SAFETY VALVE (WITH SUCTION)
ORBIT-ROLL VALVE
STOP VALVE
DIVERTER VALVE
BRAKE
BRAKE PIPING
BRAKE CIRCUIT DIAGRAM
BRAKE VALVE
RIGHT BRAKE VALVE
LEFT BRAKE VALVE
CHARGE VALVE
ACCUMULATOR (FOR BRAKE)
SLACK ADJUSTER
BRAKE
PARKING BRAKE
PARKING BRAKE CONTROL
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
HYDRAULIC
HYDRAULIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
MACHINES WITH STANDARD SPECIFICATIONS
WORK EQUIPMENT LEVER LINKAGE
HYDRAULIC TANK
OIL FILTER BY-PASS VALVE
BREATHER
ACCUMULATOR (FOR PPC VALVE)
PPC VALVE
FOR BUCKET / BOOM
FOR OPTIONAL ATTACHMENT
PPC VALVE NEUTRAL POSITION
PPC VALVE POSITIONS FUNCTIONS
PPC RELIEF VALVE
CUT-OFF VALVE
ECSS CONTROL VALVE
MAIN CONTROL VALVE
2-SPOOL
3-SPOOL
RELIEF VALVE
SAFETY VALVE (WITH SUCTION)
FLOAT SELECTOR VALVE AND UNLOAD VALVE
BOOM AND DUMP SPOOLS AT HOLD POSITION
BOOM SPOOL AT RAISE POSITION
BOOM SPOOL AT LOWER POSITION
BOOM SPOOL AT FLOAT POSITION
BUCKET SPOOL AT DUMP POSITION
BUCKET SPOOL AT TILT POSITION
WORK EQUIPMENT
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER
BOOM KICK-OUT
PROXIMITY SWITCH
CAB
ROPS CANOPY
AIR CONDITIONER
AIR CONDITIONER PIPING
AIR CONDITIONING (GENERAL)
BASIC INFORMATION ON AIR CONDITIONERS
HEAT
TEMPERATURE
PRESSURE
HUMIDITY
PRINCIPLE OF COOLING
REFRIGERANTS
FREON-TYPE GASES
SAFETY PRECAUTIONS
REFRIGERATOR OIL (LUBE OIL)
AIR CONDITONING CONDENSER
AIR CONDITIONER COMPRESSOR
RECEIVER WITH SIGHT GLASS (LIQUID TANK)
AIR CONDITIONER UNIT
MONITOR SYSTEMS
MACHINE MONITOR SYSTEM
MAIN MONITOR
MAIN MONITOR DISPLAY FUCTION
MAIN MONITOR SWITCH FUNCTION
TROUBLE DATA DISPLAY MODE
MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION
MAINTENANCE MONITOR SWITCH FUNCTION
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM
SYSTEM STRUCTURE DIAGRAM
FUNCTION
TRANSMISSION CONTROLLER POWER SOURCE
INPUT SIGNALS
OUTPUT SIGNALS
LED DISPLAY
JOYSTICK TRANSMISSION SYSTEM
REMOTE POSITION, JOYSTICK STEERING CONTROLLER
ECSS SYSTEM
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
SENSORS
SPEEDOMETER SENSOR
ENGINE SPEED SENSOR
ENGINE OIL PRESSURE SENSOR
RADIATOR WATER LEVEL SENSOR
ENGINE OIL LEVEL SENSOR
FUEL LEVEL SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
PREHEATING CIRCUIT
ELECTRICAL TRANSMISSION CONTROL
COMBINATION SWITCH
KICK-DOWN / HOLD SWITCH
KICK-DOWN SWITCH
HOLD SWITCH
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS
NORMAL OPERATION
WHEN KICK-DOWN SWITCH IS OPERATED
KICK-DOWN SWITCH OPERATION CANCELED
ELECTRIC PARKING BRAKE CONTROL
PARKING BRAKE EMERGENCY RELEASE SWITCH
EMERGENCY BRAKE SWITCH
PARKING SAFETY RELAY
NEUTRALIZER RELAY
ELECTRICAL DIAGRAM
ECSS WIRING DIAGRAM - FOLDOUT
JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT
ELECTRICAL CIRCUIT DIAGRAM
ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT
CAB ELECTRICAL DIAGRAM - FOLDOUT
ENGINE HARNESS DIAGRAM
ENGINE - FRAME - FLOOR HARNESS DIAGRAM

TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR CHASSIS
SKETCHES OF SPECIAL TOOLS
ENGINE
COMPONETS
BLEEDING AIR FROM FUEL SYSTEM
BLOW-BY PRESSURE
COMPRESSION PRESSURE
EXHAUST TEMPERATURE
FUEL PRESSURE
HANDLING EQUIPMENT IN FUEL CIRCUIT
INTAKE AIR PRESSURE (BOOST PRESSURE)
LEAKAGE IN FUEL SYSTEM
OIL PRESSURE
PERFORMANCE TEST STANDARDS
RELEASING REMAINING PRESSURE IN FUEL SYSTEM
RUN-IN STANDARD
SPEED SENSOR
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
VALVE CLEARANCE
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT
REDUCED CYLINDER MODE
ALTERNATOR BELT TENSION
FAN BELT TENSION
AIR CONDITIONER BELT
TORQUE CONVERTER STALL SPEEDS
SHIFT LEVERS
OPERATING FORCE OF SPEED LEVER
TRAVEL OF SPEED LEVER
ACCELERATOR PEDAL
OPERATING FORCE
OPERATING ANGLE
TORQUE CONVERTER AND TRANSMISSION
OIL PRESSURE
HYDRAULIC CIRCUIT FLUSHING
TRANSMISSION VALVE FAILS - MOVING MACHINE
STEERING WHEEL
MEASURING PLAY
MEASURING OPERATING FORCE
MEASURING OPERATING TIME
STEERING OIL PRESSURE
STEERING STOP VALVE
BRAKE PEDAL
OPERATING FORCE
TRAVEL
PEDAL PLAY
BRAKE PERFORMANCE
TESTING BRAKE OIL PRESSURE
BRAKE DISC WEAR
PARKING BRAKE
OIL PRESSURE
DISC WEAR
MANUAL RELEASE METHOD
PPC VALVE
OIL PRESSURE
ADJUSTING LINKAGE
ACCUMULATOR
CHARGE PRESSURE
WORK EQUIPMENT
HYDRAULIC PRESSURE
ADJUSTING
CUT-OFF VALVE
TESTING FUNCTION
PROCEDURE
LEVER LINKAGE
BUCKET POSITIONER
BOOM KICK-OUT POSITIONER
TRANSMISSION CONTROLLER
INITIAL TEACHING METHOD
MAIN MONITOR
ADJUSTMENT PROCEDURE
BLEEDING AIR
RELEASING REMAINING HYDRAULIC OIL PRESSURE
ADJUSTING JOYSTICK LEVER POTENTIOMETER
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH
TROUBLESHOOTING - GENERAL
ELECTRICAL CONNECTORS
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL MECHANISM)
TROUBLESHOOTING SYSTEMS OF:
D MODE - ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)
E MODE - CHASSIS ELECTRICAL SYSTEM
H MODE - HYDRAULIC AND MECHANICAL SYSTEMS
J MODE - JOYSTICK STEERING CONTROLLER SYSTEM

DISASSEMBLY AND ASSEMBLY
PRECAUTIONS DURING OPERATION
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
OTHER PRECAUTIONS
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
ENGINE
COMPONENTS
ALTERNATOR
CYLINDER HEAD
ENGINE FRONT SEAL
ENGINE OIL COOLER
ENGINE REAR SEAL
FUEL INJECTION PUMP
NOZZLE HOLDER
STARTING MOTOR
THERMOSTAT
TURBOCHARGER
WATER PUMP
DAMPER
TORQUE CONVERTER AND TRANSMISSION
DISCONNECTION
CONNECTION
TORQUE CONVERTER
TRANSMISSION
TRANSFER
PARKING BRAKE
TRANSMISSION CONTROL VALVE (ECMV)
CENTER SUPPORT
DRIVE SHAFT
FRONT AXLE
REAR AXLE
DIFFERENTIAL
REMOVAL / INSTALLATION
DISASSEMBLY DIFFERENTIAL GEAR ASSEMBLY
FINE DISASSEMBLY OF PINION ASSEMBLY
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY
FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY
FINE ASSEMBLY OF PINION ASSEMBLY
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
DISSASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY
FINE DISASSEMBLY OF PINION ASSEMBLY
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY
FINE ASSEMBLY OF PINION ASSEMBLY
ASSEMBLY OF DIFFERENTIAL ASSEMBLY
DISASSEMBLY OF FINAL DRIVE ASSEMBLY
ASSEMBLY OF FINAL DRIVE ASSEMBLY
STEERING ORBITAL VALVE
ENSURE A CLEAN WORKING ENVIRONMENT
PREPARATORY WORK
STEERING CYLINDER
STEERING VALVE
BRAKE VALVE
SLACK ADJUSTER
BRAKE ASSEMBLY (FRONT AND REAR)
HYDRAULIC PUMP
HYDRAULIC TANK
HYDRAULIC FILTER
PPC VALVE
MAIN CONTROL VALVE
BUCKET CYLINDER
BOOM CYLINDER
CENTER HINGE PIN
WORK EQUIPMENT
BULKHEAD
ENGINE HOOD
CAB

MAINTENANCE STANDARD

ELECTRICAL DIAGRAM
HYDRAULIC SCHEMATIC

Engine SA6D140E-3 workshop service repair manual