PDF Shop Manual Komatsu WA500-1LC Wheel Loader - 6 MB
This comprehensive shop manual is the definitive guide for servicing the Komatsu WA500-1LC Wheel Loader.
It provides technicians with detailed, step-by-step procedures for repair and maintenance.
The manual includes sections on troubleshooting, testing, and adjusting, as well as complete disassembly and assembly instructions.
Trust this factory manual to help you maintain the high performance and reliability of your Komatsu wheel loader.
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--- Page 1 ---
CEBM022903
Shop
Manual
WA500-6
WHEEL LOADER
SERIAL NUMBERS WA500-6 A93001 and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
December 2013 Copyright 2013 Komatsu
Printed in USA DataKom Publishing Division
00-1d
--- Page 3 ---
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended by Komatsu and described in this manual are both effective and safe. Some of these operations require the use
of tools specially designed for the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying
this symbol should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety
and take the necessary actions to deal with the situation.
General Precautions 00
5. Keep all tools in good condition and learn the correct
way to use them.
Mistakes in operation are extremely dangerous. Read the
Operation & Maintenance Manual carefully BEFORE 6. Only qualified workers must carry out work and
operating the machine. operations which require a license or qualification.
1. Before carrying out any greasing or repairs, read all the 7. Decide a place in the repair workshop to keep tools and
precautions given on the decals which are fixed to the removed parts. Always keep the tools and parts in their
machine. For the locations of the labels and detailed correct places. Always keep the work area clean and
explanation of the precautions, see the Operation & make sure that there is no dirt or oil on the floor. Smoke
Maintenance Manual. only in the areas provided for smoking. Never smoke
while working.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes or 8. Avoid working for long hours and take rests at proper
clothes with buttons missing. intervals to keep your body in good condition. Take
rests in specified safe places.
โข Always wear safety glasses when hitting parts with
a hammer. Safety Points
โข Always wear safety glasses when grinding parts
with a grinder, etc. 1 Good arrangement
2 Correct work clothes
3. If welding repairs are needed, always have a trained,
3 Following work standard
experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron, 4 Making and checking signs
glasses, cap, and other clothes suited for welding work. Prohibition of operation and handling by
5
unlicensed workers
WARNING! Never modify, weld, cut, or drill on
6 Safety check before starting work
any part of a ROPS structure.
Wearing protective goggles
Doing so may weaken the structure 7
(for cleaning or grinding work)
which could lead to possible failure
in a rollover situation. Wearing shielding goggles and protectors
8
(for welding work)
4. When carrying out any operation with two or more 9 Good physical condition and preparation
workers, always agree on the operating procedure Precautions against work which you are not
before starting. Always inform your fellow workers 10 used to or work with which you are too
before starting any step of the operation. Before starting familiar
work, hang UNDER REPAIR warning signs on the
controls in the operatorโs compartment.
WA500-6 00-3
--- Page 4 ---
FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
โข While pressing up lock (C) of the connector with flat-head screw-
driver [1], pull out connector (3) in the direction of the arrow.
โ
107, 114 engines
Connector Sensor
Intake air pressure/temperature sensor
SUMITOMO-04
in intake manifold
โข While pressing lock (D), pull out connector (4) in the direction of
the arrow.
โ
95, 125 โ 170, 12V140 engines
โข While pressing lock (E) of the connector, pull out connector (5) in
the direction of the arrow.
Connector Sensor
Fuel pressure sensor in common rail:
AMP-3
PFUEL, etc.
Connector Valve
Injection pressure control valve of fuel
SUMITOMO-2
supply pump: PCV
WA500-6 00-23
--- Page 5 ---
FOREWORD CONVERSION TABLES
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
WA500-6 00-43
--- Page 6 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
Specifications
Hydraulic Oil Hydraulic Oil Torque Converter
Radiator Aftercooler
Cooler (1) Cooler (2) Oil Cooler
Aluminum tube Straight fin
Core type PTO-OL PTO-OL PTO-LS
in 4-column 10-hole tube type
Fin pitch 4.0/2P 100 x 385 x 17 100 x 558 x 17 6.0/2P 150 x 620 x 20-stage
mm (in) (0.16/2P) (3.9 x 15.2 x 0.7) (3.9 x 22.0 x 0.7) (0.24/2P) (5.9 x 24.4 x 20-stage)
Total heat dissipation
surface 59.90 1.2187 1.829 21.57 3.254
(644.76) (13.118) (19.687) (232.18) (35.026)
m2 (ft2)
Cross-sectional area of
flow 50.845
โ โ โ โ
(7.881)
cm2 (in2)
Pressure valve cracking
0.714 ยฑ0.153
pressure โ โ โ โ
(10 ยฑ2)
kg/cmยฒ (psi)
Vacuum valve cracking
0 โ 0.051
pressure โ โ โ โ
(0 โ 1)
kg/cmยฒ (psi)
WA500-6 10-9 b
--- Page 7 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
1. Output shaft
2. Case
3. Thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Center spring
9. Check valve
10. Pilot valve
11. Reversible valve spool
12. Safety valve
No. Check Item Criteria Remedy
Standard Size Repair Limit
Free Length x
Installed
Outside Installed Free Installed
Length
13 Spool return spring Diameter Load Length Load If damaged or
mm (in)
mm (in) deformed, replace
44.8 x 12.0 58.8 N 47.1 N spring
33.0 (1.30) โ
(1.76 x 0.47) (13.22 lbf) (10.59 lbf)
13.0 x 6.5 1.96 N 1.57 N
14 Check valve spring 9.5 (0.37) โ
(0.51 x 0.26) (0.44 lbf) (0.35 lbf)
Torque Values
Item Nโขm lbf in
D 9.8 โ 12.7 87 โ 112
WA500-6 10-29 b
--- Page 8 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD POWER TRAIN
Unit: mm (in)
No. Check Item Criteria Remedy
Standard Size Tolerance Repair Limit
1 Outside diameter of pilot -0.040 (-0.0016) Repair by hard
80 (3.15) 79.92 (3.15)
-0.070 (-0.0028) chromium-plating
or replace
Inside diameter of sleeve seal ring +0.030 (+0.0012)
65 (2.56) 65.1 (2.56)
contact surface โ0 (0)
2 -0.01 (-0.0004)
Wear of output shaft seal Width 3 (0.12) 2.7 (0.11)
-0.03 (-0.0012) Replace
ring
Thickness 2.7 (0.11) ยฑ0.1 (ยฑ0.0039) 2.55 (0.10)
Repair by hard
Inside diameter of PTO drive gear seal +0.040 (+0.0016)
3 170 (6.70) 170.5 (6.71) chromium-plating
ring contact surface โ0 (0)
or replace
Tolerance
Standard Size
Shaft Hole
Tolerance for fitness of Outside โ0.(0)000 -0.028 (-0.0011)
4 125 (4.92)
PTO idler gear bearing diameter -0.020 (-0.0008) -0.068 (-0.0027)
Inside +0.012 (+0.0005) โ0 (0).000
70 (2.76)
diameter -0.007 (-0.0003) -0.015 (-0.0006)
Outside โ0 (0)0 -0.012 (-0.0005)
Tolerance for fitness of 150 (5.91)
diameter -0.020 (-0.0008) -0.052 (-0.0020)
5 input transfer drive gear
bearing (Large) Inside +0.059 (+0.0023) โ0 (0)00
85 (3.35)
diameter +0.037 (+0.0015) -0.020 (-0.0008)
Outside โ0 (0)0 -0.012 (-0.0005)
Tolerance for fitness of 140 (5.51)
diameter -0.020 (-0.0008) -0.052 (-0.0020)
6 input transfer drive gear
bearing (Small) Inside +0.051 (+0.0020) โ0.(0)000
80 (3.15)
diameter +0.032 (+0.0013) -0.015 (-0.0006)
Replace
Outside โ0 (0)000 -0.012 (-0.0005)
Tolerance for fitness of 125 (4.92)
diameter -0.020 (-0.0008) -0.052 (-0.0020)
7 input transfer driven gear
bearing Inside +0.051 (+0.0020) โ0.(0)000
80 (3.15)
diameter +0.032 (+0.0013) -0.015 (-0.0006)
Backlash between PTO drive gear and
8 0.192 โ 0.492 (0.0076 โ 0.0194)
PTO idler gear
Backlash between input transfer drive
9 0.190 โ 0.486 (0.0075 โ 0.0191)
gear and driven gear
Standard Clearance Clearance Limit
Clearance between cage and case of 0.40 โ 1.60 (0.016 โ 0.063)
10
input transfer drive gear (Standard shim thickness: โ
1.0 (0.039))
0.60 โ 1.80 (0.024 โ 0.071)
Clearance between cage and case of
11 (Standard shim thickness: โ
input transfer driven gear
1.0 (0.039))
WA500-6 10-49 b
--- Page 9 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD POWER TRAIN
1. Transmission input shaft 24. 2nd piston return spring
2. Tie bolt 25. 2nd clutch piston
3. R ring gear (Hub) 26. 2nd clutch housing
4. R planetary pinion (Number of teeth: 24) 27. 3rd and 4th carriers
5. R ring gear (Number of teeth: 70) 28. 3rd piston return spring
6. F planetary pinion (Number of teeth: 23) 29. 3rd clutch piston
7. F ring gear (Number of inside teeth: 75) 30. 3rd and 4th clutch housings
8. 4th ring gear (Number of inside teeth: 73) 31. 4th clutch piston
9. 4th planetary pinion (Number of teeth: 28) 32. 4th piston return spring
10. 3rd planetary pinion (Number of teeth: 20) 33. F and 4th clutch cages
11. 3rd ring gear (Number of inside teeth: 76) 34. F piston return spring
12. 2nd ring gear (Number of teeth: 76) 35. F sun gear (Number of teeth: 29)
13. 2nd planetary pinion (Number of teeth: 20) 36. F carrier
14. 1st hub 37. F clutch piston
15. Transmission output shaft (4th sun gear) (Number of teeth: 17) 38. R and F clutch housings
16. Transfer input gear (Number of teeth: 50) 39. R clutch piston
17. 2nd sun gear (Number of teeth: 36) 40. Washer spring
18. 1st clutch housing 41. R piston return spring
19. 1st clutch piston 42. R carrier
20. 2nd carrier 43. Clutch disc
21. 3rd sun gear (Number of teeth: 36) 44. Clutch plate
22. 1st piston return spring 45. R clutch cage
23. 2nd clutch housing 46. R sun gear (Number of teeth: 22)
WA500-6 10-69 b
--- Page 10 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD POWER TRAIN
โ
R ring gear (7) of R clutch and 1st hub (16) of 1st clutch are fixed hydraulically.
The power from torque converter
๏ฏ
Input shaft (1)
๏ฏ
R sun gear (5)
๏ฏ
R planetary pinion (6)
๏ฏ
R ring gear (9)
(R carrier (8) is fixed with R ring
gear (7) = R ring gear (9) rotation
direction is opposite to input shaft (1))
๏ฏ
F carrier (10)
๏ฏ
3rd and 4th carrier (11)
๏ฏ
3rd planetary pinion (12) ๏ฎ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ฎ
๏ฏ ๏ฏ
3rd ring gear (13) 3rd sun gear (20)
๏ฏ
2nd carrier (14)
๏ฏ
1st clutch housing (15) ๏ฏ
๏ฏ
1st hub (16)
๏ฏ
Output shaft (23) ๏ฌ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ ๏ฌ
WA500-6 10-89 b
--- Page 11 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD POWER TRAIN
Unit: mm (in)
No. Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between Size Clearance Limit
Shaft Hole
1 main relief valve and
valve body -0.035 (-0.0014) +0.013 (+0.0005) 0.035 โ 0.058 0.078
28 (1.10)
-0.045 (-0.0018) +0 (0).000 (0.0014 โ 0.0023) (0.0031)
Clearance between
-0.035 (-0.0014) +0.013 (+0.0005) 0.035 โ 0.058 0.078
2 torque converter relief 22 (0.87)
-0.045 (-0.0018) +0.(0).00 (0.0014 โ 0.0023) (0.0031)
valve and valve body
Standard Size Repair Limit
Replace
Free Installed Installed
Main relief valve spring Installed Load Free Length
3 Length Length Load
(Outside)
479.1 N 456 N
128 (5.04) 78.3 (3.08) 124.2 (4.89)
(107.71 lbf) (102.51 lbf)
Main relief valve spring 365.5 N 347 N
4 108 (4.25) 78.3 (3.08) 104.8 (4.13)
(Inside) (82.17 lbf) (78.01 lbf)
Torque converter relief 134.3 N 127 N
5 50 (1.97) 43 (1.69) 48.5 (1.91)
valve spring (30.19 lbf) (28.55 lbf)
Torque Values
Designation Nโขm lbf ft lbf in
AA 9.8 โ 12.74 โ 87 โ 113
BB 44.1โ 53.9 33 โ 40 โ
WA500-6 10-109 b
--- Page 12 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD POWER TRAIN
Rear Differential (with Limited Slip Differential)
1. Pinion gear (Number of teeth: 12)
2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 38)
WA500-6 10-129 b
--- Page 13 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD STEERING SYSTEM
Unit: mm (in)
No Check Item Criteria Remedy
Standard Size Repair Limit
Free Installed Installed Free Allowable
1 Steering spool return spring Length Length Load Length Load
56.9 N 45.1 N
37.2 (1.46) 32.0 (1.26) โ
(12.79 lbf) (10.14 lbf)
2.9 N 2.5 N Replace
2 Load check valve spring 20.9 (0.82) 18.3 (0.72) โ
(0.65 lbf) (0.56 lbf)
147.1 N 120.6 N
3 Unload spool return spring 69.7 (2.74) 68.5 (2.70) โ
(33.07 lbf) (27.11 lbf)
22.19 182.4 N 145.1 N
4 Relief valve spring 24.0 (0.94) โ
(0.87) (41.01 lbf) (32.62 lbf)
WA500-6 10-149 b
--- Page 14 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD STEERING SYSTEM
Emergency Steering (if equipped)
Piping Diagram
1. Diverter valve
2. Steering pump
3. Hydraulic tank
4. Emergency steering pump
5. Transmission
WA500-6 10-169 b
--- Page 15 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD BRAKE SYSTEM
Operation
โ
When oil is not supplied to accumulator (Cutout state)
โข Since the pressure at port (B) is higher than the set pressure of
relief valve (R1), piston (2) is forced to move upward by the
hydraulic pressure of port (B). As this move opens poppet (1),
port (C) and port (T) are connected.
โข As the right-most spring chamber of spool (6) leads to port (C) of
relief valve (R1), tank pressure prevails.
โข Oil from the pump enters port (P) and pushes spool (6) to the right
with a low pressure equivalent to the load of spring (5), and then
flows from port (A) to the steering valve and the work equipment
valve.
โข At the same time, it flows to the tank through orifices (7), (4), and
(3).
โ
When oil is supplied to accumulator
1. Cut-in state
โข If the pressure at port (B) drops below the set pressure of relief
valve (R1), piston (2) is returned downward by the tension of
spring (8). This causes valve seat (9) to closely contact
poppet (1) to disconnect port (C) from port (T).
โข The right-hand side spring chamber of spool (6) also gets
shuttered off from port (T) to increase pressure, leading
pressure at port (P) to rise as well.
โข When pressure at port (P) exceeds the pressure at port (B)
(accumulator pressure), oil supply to the accumulator starts.
This timing is determined by the area size of orifice (7) and
the pressure differential before and after (equivalent to the
load of spring (5)). A fixed amount of oil is supplied
regardless of the engine speed; the remaining amount flows to
port (A).
WA500-6 10-189 b
--- Page 16 ---
STRUCTURE, FUNCTION AND ๏
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
Unit: mm (in)
No. Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Size Shaft Hole Clearance Limit
Clearance between hole and shaft
1 on front support side (after press- -0.056
fitting of bushing) +0.489
310 (-0.002) 0.056 โ 0.626 1.6
(+0.019)
(12.20) -0.137 (0.002 โ0.025) (0.063)
0 (0)
(-0.005)
+2.300 Replace
Clearance between hole and shaft +0.089 (Bushing is
320.2 (+0.091)
2 on front support side (before (+0.0035) โ โ adhered to
(12.61) +0.800
press-fitting of bushing) 0 (0) support on
(+0.031)