Komatsu wa500 6 galeo wheel loader service repair manual (wa500 6 serial 55001 and up)

SEN00236-05

WHEEL LOADER

WA500 -6 SERIAL NUMBERS

55001

and up

SEN00701-05

WHEEL LOADER 1SHOP MANUAL

WA500-6

Machine model

Serial number

WA500-6

55001 and up

00 Index and foreword

1

Index Composition of shop manual................................................................................................................ 2 Table of contents .................................................................................................................................. 4

WA500-6

1

SEN00701-05

00 Index and foreword

Composition of shop manual

1

The contents of this shop manual are shown together with Form No. in a list.

Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.

The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly.

Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00236-05

00 Index and foreword Index Foreword and general information

SEN00575-05 SEN00701-05 q SEN00702-02 q

01 Specification Specification and technical data

SEN00576-01 SEN00703-01 q

10 Structure, function and maintenance standard Engine and cooling system Power train, Part 1 Power train, Part 2 Steering system Brake system Undercarriage and frame Hydraulic system, Part 1 Hydraulic system, Part 2 Work equipment Cab and its attachments Electrical system, Part 1 Electrical system, Part 2 Electrical system, Part 3

SEN00577-01 SEN00704-00 SEN00705-01 SEN00864-01 SEN00706-01 SEN00707-01 SEN00708-01 SEN00709-01 SEN00875-01 SEN00710-01 SEN00711-01 SEN00712-01 SEN00713-01 SEN00874-01

20 Standard value table Standard service value table

SEN00578-02 SEN00724-02

30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 Testing and adjusting, Part 4

SEN00579-02 SEN00725-02 SEN00726-02 SEN00727-01 SEN00728-01

40 Troubleshooting General information on troubleshooting Troubleshooting by failure code (Display of code), Part 1

SEN00580-01 SEN00729-00 SEN00730-01

2

q q q q q q q q q q q q

WA500-6

00 Index and foreword

Troubleshooting by failure code (Display of code), Part 2 Troubleshooting by failure code (Display of code), Part 3 Troubleshooting by failure code (Display of code), Part 4 Troubleshooting by failure code (Display of code), Part 5 Troubleshooting by failure code (Display of code), Part 6 Troubleshooting by failure code (Display of code), Part 7 Troubleshooting by failure code (Display of code), Part 8 Troubleshooting by failure code (Display of code), Part 9 Troubleshooting by failure code (Display of code), Part 10 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)

SEN00701-05

SEN00731-01 SEN00732-01 SEN00733-01 SEN00734-01 SEN00735-01 SEN00736-01 SEN00737-01 SEN00738-01 SEN00739-01 SEN00740-01 SEN00741-00 SEN00742-01

50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Engine (SAA6D140E-5) Power train, Part 1 Power train, Part 2 Power train, Part 3 Brake system Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system

SEN00581-00 SEN02022-00 SEN02023-00 SEN02024-00 SEN02025-00 SEN02026-00 SEN02027-00 SEN02028-00 SEN02029-00 SEN02030-00 SEN02031-00 SEN02032-00 SEN02033-00

90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings

SEN00582-01 SEN00714-01 q SEN00715-00

WA500-6

3

SEN00701-05

00 Index and foreword

Table of contents

1

00 Index and foreword Index SEN00701-05 Composition of shop manual ...................................................................................................

2 Table of contents......................................................................................................................

4 Foreword and general information SEN00702-02 Safety notice ............................................................................................................................

2 How to read the shop manual..................................................................................................

7 Explanation of terms for maintenance standard ......................................................................

9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data SEN00703-01 Specification and technical data ..................................................................................................

2 Specification dimension drawing..............................................................................................

2 Specifications...........................................................................................................................

3 Weight table .............................................................................................................................

6 Table of fuel, coolant and lubricants ........................................................................................

8 10 Structure, function and maintenance standard Engine and cooling system SEN00704-00 Engine and cooling system .........................................................................................................

2 Cooling system ........................................................................................................................

2 Engine mount and transmission mount ...................................................................................

5 Power train, Part 1 SEN00705-01 Power train, Part 1.......................................................................................................................

3 Power train...............................................................................................................................

3 Power train system diagram ....................................................................................................

4 Joint .........................................................................................................................................

6 Drive shaft................................................................................................................................

7 Power train piping diagram ......................................................................................................

8 Torque converter...................................................................................................................... 10 Torque converter regulator valve ............................................................................................. 28 Transmission............................................................................................................................ 30 Transfer.................................................................................................................................... 50 Transmission control valve ...................................................................................................... 52 ECMV ...................................................................................................................................... 56 Main relief valve and torque converter relief valve .................................................................. 63 Lubrication relief valve ............................................................................................................. 65 Power train, Part 2 SEN00864-01 Power train, Part 2.......................................................................................................................

2 Torque converter oil cooler ......................................................................................................

2 Torque converter oil filter .........................................................................................................

3 Center support .........................................................................................................................

6 Axle..........................................................................................................................................

8 Differential................................................................................................................................ 10 Limited slip differential ............................................................................................................. 19 Final drive ................................................................................................................................ 24

4

WA500-6

00 Index and foreword

SEN00701-05

Steering system SEN00706-01 Steering system...........................................................................................................................

2 Steering piping diagram...........................................................................................................

2 Steering column.......................................................................................................................

3 Steering control valve ..............................................................................................................

4 Steering valve .......................................................................................................................... 15 Stop valve ................................................................................................................................ 19 Joystick steering lever linkage (if equipped)............................................................................ 20 Steering cylinder ...................................................................................................................... 21 Emergency steering piping diagram (if equipped) ................................................................... 22 Diverter valve........................................................................................................................... 23 Brake system SEN00707-01 Brake system ..............................................................................................................................

2 Brake piping diagram...............................................................................................................

2 Brake valve..............................................................................................................................

4 Slack adjuster ..........................................................................................................................

9 Accumulator charge valve ....................................................................................................... 12 PPC relief valve ....................................................................................................................... 16 Accumulator (for brake) ........................................................................................................... 18 Brake ....................................................................................................................................... 20 Parking brake control............................................................................................................... 23 Parking brake .......................................................................................................................... 24 Parking brake solenoid valve................................................................................................... 26 Emergency parking brake release valve ................................................................................. 28 Undercarriage and frame SEN00708-01 Undercarriage and frame ............................................................................................................

2 Axle mount...............................................................................................................................

2 Center hinge pin ......................................................................................................................

7 Hydraulic system, Part 1 SEN00709-01 Hydraulic system, Part 1 .............................................................................................................

2 Hydraulic piping diagram .........................................................................................................

2 Work equipment control lever linkage .....................................................................................

4 Hydraulic tank..........................................................................................................................

5 Cooling fan motor ....................................................................................................................

7 Cooling fan pump .................................................................................................................... 14 Steering pump ......................................................................................................................... 21 Work equipment hydraulic pump ............................................................................................. 32 Hydraulic system, Part 2 SEN00875-01 Hydraulic system, Part 2 .............................................................................................................

2 Control valve............................................................................................................................

2 CLSS ....................................................................................................................................... 16 Each function and operation of each valve.............................................................................. 21 Accumulator (for PPC circuit) .................................................................................................. 32 Work equipment electric lever ................................................................................................. 33 Work equipment SEN00710-01 Work equipment ..........................................................................................................................

2 Work equipment linkage ..........................................................................................................

2 Bucket......................................................................................................................................

6 Bucket positioner and boom kick-out.......................................................................................

8 Work equipment lubrication .....................................................................................................

9 Cab and its attachments SEN00711-01 Cab and its attachments..............................................................................................................

2 ROPS cab................................................................................................................................

2 Air conditioner..........................................................................................................................

4 Electrical system, Part 1 SEN00712-01 Electrical system, Part 1..............................................................................................................

2 WA500-6

5

SEN00701-05

00 Index and foreword

Machine monitor system..........................................................................................................

2 Machine monitor ...................................................................................................................... 10 Electrical system, Part 2 SEN00713-01 Electrical system, Part 2..............................................................................................................

2 Work equipment control system ..............................................................................................

2 Transmission controller system ............................................................................................... 36 Electrical system, Part 3 SEN00874-01 Electrical system, Part 3..............................................................................................................

2 Electric transmission control ....................................................................................................

2 Engine starting circuit ..............................................................................................................

6 Engine stopping circuit.............................................................................................................

8 Preheating circuit .....................................................................................................................

9 Parking brake circuit ................................................................................................................ 11 Backup and stop lamp circuits ................................................................................................. 16 Small lamp and head lamp circuits .......................................................................................... 18 Working lamp circuit ................................................................................................................ 19 Horn circuit............................................................................................................................... 20 Wiper and window washer circuits........................................................................................... 21 Sensor ..................................................................................................................................... 24 KOMTRAX terminal system (if equipped)................................................................................ 42 20 Standard value table Standard service value table SEN00724-02 Standard service value table .......................................................................................................

2 Standard service value table for engine...................................................................................

2 Standard service value table for chassis .................................................................................

3 30 Testing and adjusting Testing and adjusting, Part 1 SEN00725-02 Testing and adjusting, Part 1 .......................................................................................................

3 Tools for testing, adjusting, and troubleshooting......................................................................

3 Measuring engine speed .........................................................................................................

6 Measuring exhaust gas color...................................................................................................

8 Measuring exhaust temperature .............................................................................................. 10 Adjusting valve clearance ........................................................................................................ 12 Testing compression pressure ................................................................................................. 13 Measuring blow-by pressure.................................................................................................... 15 Measuring engine oil pressure................................................................................................. 16 Measuring intake air (boost) pressure ..................................................................................... 17 Handling fuel system equipment.............................................................................................. 19 Releasing residual pressure in fuel system ............................................................................. 19 Testing fuel pressure................................................................................................................ 20 Testing return rate and leakage ............................................................................................... 21 Bleeding air from fuel circuit .................................................................................................... 24 Testing leakage in fuel system................................................................................................. 26 Handling reduced cylinder mode operation ............................................................................. 27 Handling no injection cranking operation................................................................................. 27 Handling controller voltage circuit............................................................................................ 28 Testing and adjusting alternator belt tension ........................................................................... 29 Testing and adjusting air conditioner compressor belt tension ................................................ 30 Adjusting transmission speed sensor ...................................................................................... 31 Measuring directional lever (Steering wheel specification) ...................................................... 33 Testing and adjusting power train oil pressure......................................................................... 34 Flushing procedure for torque converter and transmission hydraulic circuit............................ 47 Method of moving machine when transmission valve is broken.............................................. 50

6

WA500-6

00 Index and foreword

SEN00701-05

Testing and adjusting, Part 2 SEN00726-02 Testing and adjusting, Part 2.......................................................................................................

3 Testing and adjusting steering stop valve................................................................................

3 Testing and adjusting steering wheel.......................................................................................

5 Testing steering oil pressure....................................................................................................

7 Bleeding air from steering cylinder circuit................................................................................ 10 Testing hydraulic drive fan ....................................................................................................... 11 Bleeding air from hydraulic drive fan circuit............................................................................. 14 Measuring brake pedal ............................................................................................................ 16 Measuring brake performance................................................................................................. 17 Testing and adjusting accumulator charge pressure ............................................................... 18 Testing wheel brake oil pressure ............................................................................................. 20 Measuring wear of wheel brake disc ....................................................................................... 22 Bleeding air from brake circuit ................................................................................................. 23 Releasing residual pressure in brake accumulator circuit ....................................................... 25 Testing parking brake performance ......................................................................................... 26 Measuring parking brake oil pressure ..................................................................................... 27 Testing wear of parking brake disc .......................................................................................... 30 Method of releasing parking brake manually ........................................................................... 31 Measuring and adjusting work equipment control lever .......................................................... 32 Testing and adjusting work equipment PPC oil pressure ........................................................ 33 Measuring work equipment oil pressure.................................................................................. 35 Bleeding air from work equipment circuit................................................................................. 41 Releasing residual pressure in work equipment circuit ........................................................... 42 Method of moving machine when removing operator cab (when splittable cab is used)......... 43 Testing and adjusting bucket positioner................................................................................... 44 Testing and adjusting lift arm position detecting lever ............................................................. 46 Checking proximity switch operation indication lamp .............................................................. 47 Procedure for testing diodes.................................................................................................... 48 Preparations for work on troubleshooting of electrical system ................................................ 49 Testing and adjusting, Part 3 SEN00727-01 Testing and adjusting, Part 3.......................................................................................................

2 Starting KOMTRAX terminal operations (if equipped) .............................................................

2 Indicator lamps of KOMTRAX terminal (if equipped)...............................................................

8 Machine monitor-based adjustment at replacement, disassembly and assembly, and additional installation for each sensor and controller ................................................ 11 Special functions of machine monitor (EMMS)........................................................................ 13 Testing and adjusting, Part 4 SEN00728-01 Testing and adjusting, Part 4.......................................................................................................

2 Special functions of machine monitor (EMMS)........................................................................

2 Pm click inspection table ......................................................................................................... 40

WA500-6

7

SEN00701-05

00 Index and foreword

40 Troubleshooting General information on troubleshooting SEN00729-00 General information on troubleshooting ......................................................................................

2 Points to remember when troubleshooting ..............................................................................

2 Sequence of events in troubleshooting....................................................................................

3 Testing before troubleshooting.................................................................................................

4 Classification and procedures of troubleshooting ....................................................................

5 Connection table for connector pin numbers ...........................................................................

8 T-branch box and T-branch adapter table................................................................................ 31 Troubleshooting by failure code (Display of code), Part 1 SEN00730-01 Troubleshooting by failure code (Display of code), Part 1.............................................................

3 Failure codes list ........................................................................................................................

3 Before carrying out troubleshooting for electrical system.......................................................... 14 Information contained in troubleshooting table .......................................................................... 16 Failure code [1500L0] (TORQFLOW transmission : Double meshing) ..................................... 18 Failure code [15B0NX] (Transmission filter: Clogged)............................................................... 20 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...... 22 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)..... 24 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) ..... 26 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) .... 28 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) ... 30 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) .. 32 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) .. 34 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) . 36 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) .. 38 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) . 40 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)... 42 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF).. 44 Failure code [2F00MA] (Parking brake: Malfunction) ................................................................ 46 Failure code [2G42ZG] (Front accumulator: Low oil pressure) ................................................. 48 Troubleshooting by failure code (Display of code), Part 2 SEN00731-01 Troubleshooting by failure code (Display of code), Part 2...........................................................

4 Failure code [2G43ZG] (Rear accumulator: Low oil pressure) ................................................

4 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) ....................................

6 Failure code [AA1ANX] (Air cleaner: Clogging) .......................................................................

8 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............. 10 Failure code [AB00MA] (Alternator: Malfunction) .................................................................... 12 Failure code [B@BAZG] (Low engine oil pressure)................................................................. 14 Failure code [B@BAZK] (Engine oil: Low level) ...................................................................... 16 Failure code [B@BCNS] (Coolant: Overheating)..................................................................... 18 Failure code [B@BCZK] (Coolant: Low level).......................................................................... 20 Failure code [B@C7NS] (Brake oil: Overheating) ................................................................... 22 Failure code [b@CENS] (Torque converter oil: Overheating).................................................. 24 Failure code [B@CENS] (Torque converter oil: Overheating) ................................................. 26 Failure code [B@GAZK] (Battery electrolyte: Low level) ......................................................... 28 Failure code [B@HANS] (Hydraulic oil: Overheating) ............................................................. 30 Failure code [CA111] (Abnormality in engine controller).......................................................... 32 Failure code [CA115] (Engine Ne or Bkup speed sensor error) .............................................. 35 Failure code [CA122] (Charge pressure sensor high error)..................................................... 36 Failure code [CA123] (Charge pressure sensor low error) ...................................................... 38 Failure code [CA131] (Throttle sensor high error) ................................................................... 39 Failure code [CA132] (Throttle sensor low error)..................................................................... 41 Failure code [CA135] (Engine oil pressure sensor high error)................................................. 42 Failure code [CA141] (Engine oil pressure sensor low error) .................................................. 44 Failure code [CA144] (Coolant temperature sensor high error)............................................... 45 Failure code [CA145] (Coolant temperature sensor low error) ................................................ 47 Failure code [CA153] (Charge temperature sensor high error) ............................................... 48

8

WA500-6

00 Index and foreword

SEN00701-05

Failure code [CA154] (Charge temperature sensor low error) ................................................ 50 Failure code [CA187] (Sensor power supply 2 low error) ........................................................ 50 Failure code [CA221] (Atmospheric pressure sensor high error) ............................................ 51 Failure code [CA222] (Atmospheric pressure sensor low error).............................................. 53 Failure code [CA227] (Sensor power supply 2 high error) ...................................................... 54 Troubleshooting by failure code (Display of code), Part 3 SEN00732-01 Troubleshooting by failure code (Display of code), Part 3...........................................................

3 Failure code [CA234] (Engine overspeed) ..............................................................................

3 Failure code [CA238] (Ne speed sensor power supply error) .................................................

4 Failure code [CA263] (Fuel temperature sensor high error)....................................................

6 Failure code [CA265] (Fuel temperature sensor low error) .....................................................

8 Failure code [CA271] (PCV1 Short circuit) .............................................................................. 10 Failure code [CA272] (PCV1 Disconnection) .......................................................................... 12 Failure code [CA273] (PCV2 Short circuit) .............................................................................. 14 Failure code [CA274] (PCV2 Disconnection) .......................................................................... 16 Failure code [CA322] (Injector #1 (L/B #1) open/short error) .................................................. 18 Failure code [CA323] (Injector #5 (L/B #5) open/short error) .................................................. 20 Failure code [CA324] (Injector #3 (L/B #3) open/short error) .................................................. 22 Failure code [CA325] (Injector #6 (L/B #6) open/short error) .................................................. 24 Failure code [CA331] (Injector #2 (L/B #2) open/short error) .................................................. 26 Failure code [CA332] (Injector #4 (L/B #4) open/short error) .................................................. 28 Failure code [CA342] (Calibration code inconsistency)........................................................... 30 Failure code [CA351] (Injector drive circuit error) .................................................................... 31 Failure code [CA352] (Sensor power supply 1 low error) ........................................................ 34 Failure code [CA386] (Sensor power supply 1 high error) ...................................................... 36 Failure code [CA431] (Idle validation switch error).................................................................. 38 Failure code [CA432] (Idle validation action error) .................................................................. 40 Failure code [CA441] (Battery voltage low error) .................................................................... 40 Failure code [CA442] (Battery voltage high error) ................................................................... 41 Failure code [CA449] Common rail pressure high error 2 ....................................................... 41 Failure code [CA451] (Common rail pressure sensor high error)............................................ 42 Failure code [CA452] (Common rail pressure sensor low error) ............................................. 44 Failure code [CA553] (Common rail pressure high error 1)..................................................... 45 Failure code [CA554] (Common rail pressure sensor in-range error) ..................................... 46 Failure code [CA559] (Supply pump pressure very low error)................................................. 47 Failure code [CA689] (Engine Ne speed sensor error) ........................................................... 50 Failure code [CA731] (Engine Bkup speed sensor phase error) ............................................. 52 Failure code [CA757] (All continuous data lost error) .............................................................. 52 Failure code [CA778] (Engine Bkup speed sensor error) ........................................................ 54 Failure code [CA1228] (EGR valve servo error 1)................................................................... 56 Failure code [CA1625] (EGR valve servo error 2)................................................................... 57 Failure code [CA1626] (Bypass valve solenoid current high error) ......................................... 58 Failure code [CA1627] (Bypass valve solenoid current low error)........................................... 60 Failure code [CA1628] (Bypass valve servo error 1) ............................................................... 61 Failure code [CA1629] (Bypass valve servo error 2) ............................................................... 62 Failure code [CA1631] (Bypass valve lift sensor high error).................................................... 63 Failure code [CA1632] (Bypass valve lift sensor low error) ..................................................... 65 Failure code [CA1633] (KOMNET datalink timeout error) ....................................................... 65 Troubleshooting by failure code (Display of code), Part 4 SEN00733-01 Troubleshooting by failure code (Display of code), Part 4...........................................................

3 Failure code [CA1642] (EGR inlet pressure sensor low error) ................................................

3 Failure code [CA1653] (EGR inlet pressure sensor high error) ...............................................

4 Failure code [CA2185] (Throttle sensor supply voltage high error) .........................................

6 Failure code [CA2186] (Throttle sensor power supply low error) ............................................

8 Failure code [CA2249] (Supply pump pressure very low error 2)............................................

8 Failure code [CA2271] (EGR valve lift sensor high error) .......................................................

9 Failure code [CA2272] (EGR valve lift sensor low error) ......................................................... 11

WA500-6

9

SEN00701-05

00 Index and foreword

Failure code [CA2351] (EGR valve solenoid operation short circuit)....................................... 12 Failure code [CA2352] (EGR valve solenoid operation disconnect)........................................ 14 Failure code [CA2555] (Intake heater relay disconnection error) ............................................ 14 Failure code [CA2556] (Intake heater relay short circuit error) ................................................ 16 Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)............................ 18 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)....................... 20 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) .......................... 22 Failure code [D192KA] (ECSS solenoid: Disconnection) ........................................................ 24 Failure code [D192KB] (ECSS solenoid: Short circuit) ............................................................ 25 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)........................ 26 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) ......................... 28 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)............................. 30 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) ................................................................................. 32 Failure code [D5ZHKA] (Terminal C signal: Disconnection) .................................................... 34 Failure code [D5ZHKB] (Terminal C signal: Short circuit)........................................................ 36 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) ............................. 38 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) ................................................. 40 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)............................ 42 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) .................................. 44 Failure code [DAF5KP] (Machine monitor: Low output voltage) .............................................. 46 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))............................. 48 Failure code [DAQ0KK] (Transmission controller: Low source voltage) .................................. 50 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)........................... 52 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)) .............................................................................................. 54 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)........................................................................ 56 Troubleshooting by failure code (Display of code), Part 5 SEN00734-01 Troubleshooting by failure code (Display of code), Part 5...........................................................

4 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)).............................

4 Failure code [DAQRMA] (Transmission controller option setting: Malfunction) .......................

6 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system) ..............................

8 Failure code [DB90KK] Work equipment controller: Low source voltage (input) ..................... 10 Failure code [DB90KT] (Work equipment controller: Abnormality in controller) ...................... 12 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) ............................................................................................... 14 Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range) ................................................................................................. 16 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement of model selection signals)........................................................................ 18 Failure code [DB9RKR] (CAN communication with work equipment controller: Defective communication (Abnormality in target component system))............................. 20 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ................... 22 Failure code [DB9RMC] (CAN communication with work equipment controller: Defective operation) ......................................................................................................... 24 Failure code [DD15LD] (t switch (Panel switch 1): Switch is kept pressed for long time)...... 26 Failure code [DD16LD] (U switch (Panel switch 2): Switch is kept pressed for long time)..... 28 Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)....... 30 Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)....... 32 Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time)................................................................................ 34 Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time)................................................................................ 36

10

WA500-6

00 Index and foreword

SEN00701-05

Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time)... 38 Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept pressed for long time)................................................................................ 40 Failure code [DD1GLD] (Load meter mode selector switch (+/â&#x20AC;&#x201C;): Switch is kept pressed for long time)................................................................................ 42 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)................................................................................ 44 Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree)....................... 46 Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit) ......... 48 Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit) .... 50 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) ........ 52 Troubleshooting by failure code (Display of code), Part 6 SEN00735-01 Troubleshooting by failure code (Display of code), Part 6...........................................................

4 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)................................................................................

4 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) ...............................

6 Failure code [DDK3KA] (Right FNR switch: Disconnection)....................................................

8 Failure code [DDK3KB] (Right FNR switch: Short circuit) ....................................................... 10 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) ................................. 12 Failure code [DDK4KB] (Joystick steering FNR switch: Short circuit) ..................................... 14 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) .. 16 Failure code [DDK6KA] (FNR lever switch: Disconnection) .................................................... 18 Failure code [DDK6KB] (FNR lever switch: Short circuit) ........................................................ 22 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)..................... 24 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)................................................................................ 26 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ................. 28 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) .......................... 30 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) ..... 32 Failure code [DF10KA] (Transmission shift lever switch: Disconnection)................................ 34 Failure code [DF10KB] (Transmission shift lever switch: Short circuit) ................................... 38 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) ..................... 40 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) ......................... 42 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)........... 44 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) ........................ 46 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ........ 48 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 50 Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) ............ 52 Troubleshooting by failure code (Display of code), Part 7 SEN00736-01 Troubleshooting by failure code (Display of code), Part 7...........................................................

4 Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) ................

4 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 6 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) .

8 Failure code [DHT1KX] (Left brake pressure sensor: Out of input signal range) .................... 10 Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine) ....................................... 12 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)................. 14 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) ................................................................................. 18 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) .. 21 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection).................. 24 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) ................................................................................. 27 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ................. 30 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) ................................................................................. 33 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) .. 36

WA500-6

11

SEN00701-05

00 Index and foreword

Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)................... 39 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) ................................................................................. 42 Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection).................................................................................................................. 45 Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line) ................................................................................. 47 Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree) .................................................................................................. 49 Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection).................................................................................................................. 52 Troubleshooting by failure code (Display of code), Part 8 SEN00737-01 Troubleshooting by failure code (Display of code), Part 8...........................................................

4 Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line) .................................................................................

4 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) ..

6 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) .................................................................................

8 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) ... 10 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line) ................................................................................. 12 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) .................................................................................................. 14 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) ................................................ 18 Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) ............................... 20 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) ............... 22 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ............................................. 24 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)..................... 26 Failure code [DLF1LC] (Transmission input shaft speed sensor: Speed signals disagree) ...... 28 Failure code [DLT4KB] (Transmission output shaft speed sensor: Short circuit) ...................... 30 Failure code [DLT4KX] (Transmission output shaft speed sensor: Out of input signal range).. 32 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) .............................. 34 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) ................. 36 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) ................ 38 Failure code [DV00KB] (Alarm buzzer: Short circuit) ................................................................ 40 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) ..................................... 42 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)......................................... 43 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) .... 44 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection).................................... 46 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ....................................... 47 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ... 48 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) .......................................... 50 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit).............................................. 52 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ......... 54 Troubleshooting by failure code (Display of code), Part 9 SEN00738-01 Troubleshooting by failure code (Display of code), Part 9...........................................................

3 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) ...................................

3 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit).......................................

4 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) ..

6 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) .............................................

8 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)................................................. 10 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)............. 12 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) ...................... 14 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) .......................... 14 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) ................................................................................. 15 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) .................. 16

12

WA500-6

00 Index and foreword

SEN00701-05

Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...................... 18 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) ................................................................................. 20 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) ................... 22 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ....................... 24 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) ................................................................................. 26 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .................... 28 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ........................ 30 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) ................................................................................. 32 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) ........................ 34 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) ............................ 36 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)........................................................................................ 38 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) ......................................... 40 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)............................................. 41 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) ........ 42 Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) ......................................... 43 Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit)............................................. 44 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) .......................................... 45 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).............................................. 46 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ......... 48 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ...................................... 50 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) .......................................... 52 Troubleshooting by failure code (Display of code), Part 10 SEN00739-01 Troubleshooting by failure code (Display of code), Part 10.........................................................

4 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ......

4 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) .....................................

6 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) .........................................

8 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..... 10 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ...................................... 12 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).......................................... 14 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ..... 16 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)......................................... 18 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ............................................ 20 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ........ 22 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) ......................................... 24 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)............................................. 26 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) ........ 28 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...................................... 30 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) ......................................... 32 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) ..... 34 Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) ........................ 36 Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit) ........................... 37 Failure code [DXHJKY] (3rd valve extract EPC solenoid: Short circuit with power supply line) ................................................................................. 38 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ........................ 39 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) ........................... 40 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line) ............................................................................................................ 41 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) ...................... 42 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit).......................... 44 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) ............................................................................................................ 46 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) ....................... 48 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) ........................... 50

WA500-6

13

SEN00701-05

00 Index and foreword

Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)............................................................................................................. 52 Troubleshooting of electrical system (E-mode) SEN00740-01 Troubleshooting of electrical system (E-mode) ...........................................................................

3 Before carrying out troubleshooting of electrical system .........................................................

3 Information in troubleshooting table.........................................................................................

6 E-1 Engine does not start ........................................................................................................

7 E-2 Wiper does not operate..................................................................................................... 12 E-3 Windshield washer does not operate ................................................................................ 16 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off ............. 19 E-5 Working lamp does not light up or go off........................................................................... 27 E-6 Turn signal lamp and hazard lamp do not light up or go off .............................................. 32 E-7 Brake lamp does not light or it keeps lighting up............................................................... 38 E-8 Backup lamp does not light or it keeps lighting up ............................................................ 40 E-9 Backup buzzer does not sound or it keeps sounding........................................................ 42 E-10 Horn does not sound or it keeps sounding...................................................................... 44 E-11 Alarm buzzer does not sound or it keeps sounding......................................................... 47 E-12 Air conditioner does not operate or stop ......................................................................... 49 E-13 KOMTRAX system does not work properly..................................................................... 52 Troubleshooting of hydraulic and mechanical system (H-mode) SEN00741-00 Troubleshooting of hydraulic and mechanical system (H-mode).................................................

3 Method of using troubleshooting chart.....................................................................................

3 Table of failure modes and causes ..........................................................................................

6 H-1 Machine does not start...................................................................................................... 10 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]........................................................................ 12 H-3 Torque converter lockup is not switched ON [Machine with lockup clutch (if equipped)].. 13 H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted ...................................................................................................... 14 H-5 Shocks are large at the times of starting and shifting gear ............................................... 16 H-6 Time lag is large at the times of starting and shifting gear ................................................ 18 H-7 Torque converter oil temperature is high........................................................................... 20 H-8 Steering does not turn....................................................................................................... 21 H-9 Steering does not turn [Machine with joystick steering (if equipped)] ............................... 22 H-10 Steering response is low ................................................................................................. 23 H-11 Turning response of steering is poor [machine with joystick steering (if equipped)] ....... 24 H-12 Steering is heavy............................................................................................................. 25 H-13 When machine turns, it shakes or makes large shocks.................................................. 26 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] ................................................................... 27 H-15 Wheel brake does not work or does not work well.......................................................... 28 H-16 Wheel brake is not released or it drags .......................................................................... 29 H-17 Parking brake does not work or does not work well........................................................ 30 H-18 Parking brake is not released or it drags (including emergency release system)........... 31 H-19 Lift arm does not rise ...................................................................................................... 32 H-20 Lift arm speed is low or rising force of lift arm is insufficient ........................................... 33 H-21 When rising, lift arm comes to move slowly at specific height ........................................ 34 H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) .............................................. 34 H-23 Hydraulic drifts of lift arm occur often.............................................................................. 34 H-24 Lift arm wobbles during operation................................................................................... 34 H-25 Bucket does not tilt back ................................................................................................. 35 H-26 Bucket speed is low or tilting back force is insufficient ................................................... 36 H-27 Bucket comes to operate slowly in the midst of tilting-back............................................ 37 H-28 Bucket cylinder cannot hold down the bucket................................................................. 37 H-29 Hydraulic drifts of bucket occur often .............................................................................. 37 H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to â&#x20AC;&#x153;HOLDâ&#x20AC;?) ....... 37 H-31 During operation of machine, engine speed lowers remarkably or engine stalls ............ 38

14

WA500-6

00 Index and foreword

SEN00701-05

H-32 Large shocks are made when work equipment starts and stops .................................... 38 H-33 When work equipment circuit is relieved singly, other work equipment moves .............. 38 H-34 ECSS does not operate, and pitching and bouncing occur ............................................ 39 Troubleshooting of engine (S-mode) SEN00742-01 Troubleshooting of engine (S-mode)...........................................................................................

3 Method of using troubleshooting chart ....................................................................................

3 S-1 Engine does not start easily. .............................................................................................

6 S-2 Engine does not start ........................................................................................................

8 S-3 Engine does not pick up smoothly .................................................................................... 12 S-4 Engine stops during operation .......................................................................................... 13 S-5 Engine does not rotate smoothly (Engine hunts.) ............................................................. 14 S-6 Engine lacks output (or lacks power) ................................................................................ 15 S-7 Exhaust smoke is black (Incomplete combustion) ............................................................ 16 S-8 Oil is consumed much (or exhaust gas color is blue) ....................................................... 18 S-9 Engine oil becomes contaminated quickly ........................................................................ 19 S-10 Fuel consumption is excessive ....................................................................................... 20 S-11 Coolant contains oil (blows back or reduces).................................................................. 21 S-12 Oil pressure drops........................................................................................................... 22 S-13 Oil level rises (Water, fuel in oil)...................................................................................... 23 S-14 Coolant temperature rises too high (Overheating).......................................................... 25 S-15 Abnormal noise is made ................................................................................................. 26 S-16 Vibration is excessive ..................................................................................................... 27 50 Disassembly and assembly General information on disassembly and assembly SEN02022-00 General information on disassembly and assembly....................................................................

2 How to read this manual..........................................................................................................

2 Coating materials list ...............................................................................................................

4 Special tool list.........................................................................................................................

7 Sketches of special tools ......................................................................................................... 11 Engine and cooling system SEN02023-00 Engine and cooling system .........................................................................................................

2 Removal and installation of engine assembly .........................................................................

2 Removal and installation of radiator assembly ........................................................................

7 Removal and installation of air aftercooler...............................................................................

9 Removal and installation of cooling fan and fan motor assembly............................................ 10 Removal and installation of radiator guard and cooling fan motor assembly .......................... 12 Removal and installation of fuel tank assembly....................................................................... 15 Removal and installation of hood ............................................................................................ 17 Engine (SAA6D140E-5) SEN02024-00 Engine (SAA6D140E-5) ..............................................................................................................

2 Removal and installation of fuel supply pump assembly .........................................................

2 Removal and installation of cylinder head assembly ...............................................................

6 Removal and installation of fuel injector assembly .................................................................. 17 Removal and installation of engine front seal .......................................................................... 20 Removal and installation of engine rear seal........................................................................... 22 Power train, Part 1 SEN02025-00 Power train, Part 1 ......................................................................................................................

2 Removal and installation of torque converter and transmission assembly ..............................

2 Disconnection and connection of power train unit ...................................................................

8 Disassembly and assembly of input transfer assembly........................................................... 12 Disassembly and assembly of torque converter assembly (Lockup specification).................. 19 Disassembly and assembly of torque converter assembly (Lockup-less specification) .......... 32

WA500-6

15

SEN00701-05

00 Index and foreword

Power train, Part 2 SEN02026-00 Power train, Part 2.......................................................................................................................

2 Disassembly and assembly of transmission assembly............................................................

2 Disassembly and assembly of transfer and parking brake assembly ...................................... 32 Removal and installation of front axle assembly...................................................................... 48 Removal and installation of rear axle assembly ...................................................................... 50 Power train, Part 3 SEN02027-00 Power train, Part 3.......................................................................................................................

2 Removal and installation of front differential assembly............................................................

2 Disassembly and assembly of differential assembly (LSD specification) ................................

4 Disassembly and assembly of differential assembly (LSD-less specification)......................... 18 Disassembly and assembly of final drive assembly (Front and rear) ...................................... 29 Brake system SEN02028-00 Brake system...............................................................................................................................

2 Removal and installation of brake assembly (Front and rear) .................................................

2 Disassembly and assembly of brake assembly (Front and rear).............................................

4 Disassembly and assembly of slack adjuster assembly .......................................................... 10 Disassembly and assembly of brake accumulator charge valve assembly ............................. 11 Undercarriage and frame SEN02029-00 Undercarriage and frame ............................................................................................................

2 Removal and installation of center hinge pin ...........................................................................

2 Hydraulic system SEN02030-00 Hydraulic system .........................................................................................................................

2 Removal and installation of hydraulic tank assembly ..............................................................

2 Removal and installation of cooling pump assembly ...............................................................

5 Removal and installation of fan pump assembly .....................................................................

6 Removal and installation of work equipment pump assembly .................................................

7 Removal and installation of steering, torque converter charge and EPC pump assembly ......

9 Removal and installation of work equipment valve assembly.................................................. 10 Disassembly and assembly of work equipment control valve assembly ................................. 13 Disassembly and assembly of steering cylinder assembly...................................................... 16 Disassembly and assembly of lift arm and/bucket cylinder assembly ..................................... 20 Removal and installation of steering valve assembly .............................................................. 26 Work equipment SEN02031-00 Work equipment ..........................................................................................................................

2 Removal and installation of work equipment assembly ...........................................................

2 Removal and installation of large counterweight assembly .....................................................

6 Removal and installation of small counterweight assembly.....................................................

7 Cab and its attachments SEN02032-00 Cab and its attachments..............................................................................................................

2 Removal and installation of operator's cab assembly (Separate cab and floor specification) .

2 Removal and installation of operator's cab and floor frame assembly (Cab-floor unit specification) 7 Removal and installation of operator's cab glass (Stuck glass) ............................................... 11 Disassembly and assembly of operatorâ&#x20AC;&#x2122;s seat assembly ........................................................ 20 Electrical system SEN02033-00 Electrical system .........................................................................................................................

2 Removal and installation of engine controller assembly..........................................................

2 Removal and installation of transmission controller assembly ................................................

3 Removal and installation of work equipment controller assembly ...........................................

4 Removal and installation of air conditioner unit assembly .......................................................

5

16

WA500-6

00 Index and foreword

SEN00701-05

90 Diagrams and drawings Hydraulic diagrams and drawings SEN00714-01 Power train hydraulic circuit diagram.......................................................................................

3 Brake hydraulic circuit diagram ...............................................................................................

7 Work equipment hydraulic circuit diagram............................................................................... 11 Electrical diagrams and drawings SEN00715-00 Air conditioner electrical circuit diagram ..................................................................................

3 Electrical circuit diagram (1/7) .................................................................................................

3 Electrical circuit diagram (2/7) .................................................................................................

5 Electrical circuit diagram (3/7) .................................................................................................

7 Electrical circuit diagram (4/7) .................................................................................................

9 Electrical circuit diagram (5/7) ................................................................................................. 11 Electrical circuit diagram (6/7) ................................................................................................. 13 Electrical circuit diagram (7/7) ................................................................................................. 15 Connector arrangement diagram............................................................................................. 19

WA500-6

17

SEN00701-05

WA500-6 GALEO Wheel loader Form No. SEN00701-05

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

18

SEN00702-02

WHEEL LOADER 1SHOP MANUAL

WA500-6

Machine model

Serial number

WA500-6

55001 and up

00 Index and foreword

1

Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36

WA500-6

1

SEN00702-02

Safety notice

00 Index and foreword

1

(Rev. 2007/03)

Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe.

Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols 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.

1.

2

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine.

1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.

2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.

4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment.

5) Only qualified workers must carry out work and operation which require license or qualification.

6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work.

Before starting work, warm up your body thoroughly to start work under good condition.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

2.

Precautions against work which you are not used to or you are used to too much

Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving.

2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

WA500-6

00 Index and foreword

3) 4)

3.

When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.

Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.

2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.

3) Before starting work, stop the engine.

When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts.

4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (â&#x20AC;&#x201C;) terminal first.

5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover.

7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.

WA500-6

SEN00702-02

8)

9) 10)

11)

12)

13) 14) 15)

16)

When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires.

As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.

Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.

When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed.

When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly.

When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

When measuring hydraulic pressure, check that the measuring tools are correctly assembled.

Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

3

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4.

4

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load.

2) Check the slings before starting sling work.

3) Keep putting on gloves during sling work.

(Put on leather gloves, if available.)

4) Measure the weight of the load by the eye and check its center of gravity.

5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.

6) Do not sling a load with 1 wire rope alone.

If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

7) Limit the hanging angle to 60°, as a rule.

Do not sling a heavy load with ropes forming a wide hanging angle from the hook.

When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended.

This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

00 Index and foreword

8)

When installing wire ropes to an angular load, apply pads to protect the wire ropes.

If the load is slippery, apply proper material to prevent the wire rope from slipping.

9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.

10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly.

13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN00702-02

13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state.

14) If you find an obstacle around the hoist, stop the operation.

15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

q

5.

6.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4.

1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety.

2) Observe the signs for sling work.

3) Operate the hoist at a safe place.

4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail.

5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging.

6) Do not raise or lower a load while the crane is moving longitudinally or laterally.

7) Do not drag a sling.

8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.

9) Consider the travel route in advance and lift up a load to a safe height.

10) Place the control switch on a position where it will not be an obstacle to work and passage.

11) After operating the hoist, do not swing the control switch.

12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.

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7.

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard â&#x20AC;&#x153;Zâ&#x20AC;? twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

5

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8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles.

2)

Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them.

2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.

3] Check that each O-ring is not damaged or deteriorated.

4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.

a

Example of O-ring (Fitted to every joint of hoses and tubes)

a

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

6

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How to read the shop manual q q q

1.

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1

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors.

Materials and specifications are subject to change without notice.

Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.

Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop.

For ease of understanding, the manual is divided into the following sections.

00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information.

01. Specification This section explains the specifications of the machine.

10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component.

The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.

20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.

30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.

40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.

90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

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3.

4.

00 Index and foreword

Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 â&#x20AC;Ś)

q

Revisions Revised brochures are shown in the shop manual composition table.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically.

Symbol

Item

k

Safety

a

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

4

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

3

Tightening torque

2

Coat

5

Oil, coolant

6

Drain

Remarks Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly.

Places to be coated with adhesives, etc. during assembly.

Places where oil, etc. must be added, and capacity.

Places where oil, etc. must be drained, and quantity to be drained.

5.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

8

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Explanation of terms for maintenance standard

1

The maintenance standard values necessary for judgment of products and parts are described by the following terms.

1.

Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q

Example: Standard size 120

Tolerance –0.022 –0.126

a

The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)].

Example) 120 (–0.022/–0.126)

q

Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.

The tightness of fit is decided by the tolerance.

Indication of size of rotating shaft and hole and relationship drawing of them

q

Example: Standard size 60

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Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

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2.

Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

00 Index and foreword

5.

q

3.

4.

Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

6.

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit must be replaced or repaired. q The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the “allowable value”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. q

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Handling of electric equipment and hydraulic component

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1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring.

Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage.

For this reason, it is necessary to be extremely careful when handling wiring harnesses.

2.

Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times.

2)

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

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12

3)

Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

4)

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

5)

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

00 Index and foreword

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3.

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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand.

2] q

When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

q

When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.

3]

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

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2)

14

00 Index and foreword

Connecting connectors 1] Check the connector visually.

Check that there is no oil, dirt, or water stuck to the connector pins (mating portion).

Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.

Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector.

2] Fix the connector securely.

Align the position of the connector correctly, and then insert it securely.

For connectors with the lock stopper, push in the connector until the stopper clicks into position.

3] Correct any protrusion of the boot and any misalignment of the wiring harness.

For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

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3)

Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2).

Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks.

Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally.

Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely.

(1): Male connector (2): Female connector (a), (b): Locks

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SEN00702-02

q

Disconnection

q

Connection (Example of incomplete setting of (a))

15

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4)

16

00 Index and foreword

Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.

1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air.

2] Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

3] Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

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4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller.

2) Do not place objects on top of the controller.

3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.

4) During rainy weather, do not leave the controller in a place where it is exposed to rain.

5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand).

6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

5.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors.

2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check.

3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.

4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.

1.

Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

2.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange.

Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

3.

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

4.

Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

18

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5.

Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

6.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7.

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

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Handling of connectors newly used for engines a

1.

Mainly, following engines are object for following connectors. q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

2.

1

Pull lock type (PACKARD-2) 107 – 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc.

Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

q

Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.

2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

20

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3.

SEN00702-02

Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure.

1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

q

114 engine

q

107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

3)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

a

2)

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.

While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

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q

4)

125 – 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow.

Example) Fuel pressure in common rail: PFUEL etc.

(AMP-3)

00 Index and foreword

4.

Turn-housing type (Round green connector) q 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

1)

Disconnect connector (6) according to the following procedure.

1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn.

2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

2)

Connect the connector according to the following procedure.

1] Insert the connector to the end, while setting its groove.

2] Turn housing (H1) in the direction of the arrow until it “clicks”.

Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

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How to read electric wire code a

1

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.

Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code.

Color codes are shown in Table 3.

Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.

(Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile

Symbol AV

AVS

Heat-resistant low-voltAEX age wire for automobile

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Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

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Dimensions

(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.)

1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.)

AVS Standard CovAV Standard er D AEX Standard

8

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

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3.

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Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking.

Example: “GW” means that the background is Green and marking is White.

4.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

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AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

–

R B R D Y G L

–

–

WG

–

–

–

–

–

–

–

–

–

– –

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

YW GL

– –

Gr Br – –

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Precautions when carrying out operation

1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.]

1. q q q q q q q q q q

a

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.

After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.

When draining oil, prepare a container of adequate size to catch the oil.

Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling.

To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.

Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.

Check the number and thickness of the shims, and keep in a safe place.

When raising components, be sure to use lifting equipment of ample strength.

When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.

Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal.

Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations.

1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

26

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used.

Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30

27

07049-02734

27

22.5

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2. q q q q q q q q q q q q q

a

a 3.

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Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.

Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.

Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.

Bend the cotter pins and lock plates securely.

When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive.

When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant.

Clean all parts, and correct any damage, dents, burrs, or rust.

Coat rotating parts and sliding parts with engine oil.

When press fitting parts, coat the surface with anti-friction compound (LM-P).

After fitting snap rings, check that the snap ring is fitted securely in the ring groove.

When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.

When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook.

When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle.

2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke.

3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.

4) After doing this, run the engine at normal speed.

When using the machine for the first time after repair or long storage, follow the same procedure.

Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.

Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness.

If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”.

3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage.

If any part is loosened or damaged, retighten or repair it.

Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage.

If any part is loosened or damaged, retighten or repair it.

Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.

If any part is loosened or damaged, retighten or repair it.

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4)

5)

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Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.

If any part is damaged, replace it.

2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.

If any bolt or nut is loosened, retighten it.

Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler.

If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.

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Method of disassembling and connecting push-pull type coupler k k

1

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank.

Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4).

2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

2.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

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Type 2 1.

2.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

q

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Type 3 1.

2.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

q

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Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a

The following table corresponds to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 153 – 190 15.5 – 19.5 235 – 285 23.5 – 29.5 320 – 400 33.0 – 41.0 455 – 565 46.5 – 58.0 610 – 765 62.5 – 78.0 785 – 980 80.0 – 100.0 1,150 – 1,440 118 – 147 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12

32

1

Width across flats mm 10 13 14 27

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

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2.

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Nominal No. 02 03,04 05,06 10,12 14

4.

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Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor.

363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below.

Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

WA500-6

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

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Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil.

Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

02

19

03 04 05 06 (10) (12) (14)

6.

22 24 27 32 36 41 46 55

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

mm 6 8 10 12 14

– 14 – 18 22 24 30 33 36 42

Tightening torque Bolts and nuts Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below.

Thread size mm 6 8 10 12 14

34

Thread size (mm)

Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below.

Thread size

7.

Taper seal

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

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Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.

Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1

WA500-6

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

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Conversion table

1

Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below.

Example: Method of using the conversion table to convert from millimeters to inches 1.

Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).

2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.

2.

Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm.

2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

(A)

36

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

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Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

WA500-6

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

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Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

38

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

WA500-6

00 Index and foreword

SEN00702-02

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

WA500-6

39

SEN00702-02

00 Index and foreword

Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.

When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

40

WA500-6

00 Index and foreword

WA500-6

SEN00702-02

41

SEN00702-02

WA500-6 GALEO Wheel loader Form No. SEN00702-02

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

42

SEN00703-01

WHEEL LOADER 1SHOP MANUAL

WA500-6

Machine model

Serial number

WA500-6

55001 and up

01 Specification

1

Specification and technical data Specification and technical data...................................................................................................................... 2 Specification dimension drawing .......................................................................................................... 2 Specifications ....................................................................................................................................... 3 Weight table ......................................................................................................................................... 6 Table of fuel, coolant and lubricants ..................................................................................................... 8

WA500-6

1

SEN00703-01

Specification and technical data

01 Specification

1

Specification dimension drawing1

2

WA500-6

01 Specification

SEN00703-01

Specifications

1

Machine model name

WA500-6

Weight

Serial number kg

32,230

Front wheel load

kg

15,090

Rear wheel load

kg

17,140

Bucket capacity (Heaped)

Performance Dimension

3

m

5.6 (with Bolt-on cutting edge)

kN {kg}

90.7 {9,250}

Travel speed F1

km/h

7.7

Travel speed F2

km/h

12.5

Travel speed F3

km/h

22.3

Travel speed F4

km/h

34.9

Travel speed R1

km/h

8.6

Travel speed R2

km/h

13.0

Travel speed R3

km/h

24.8

Travel speed R4

km/h

37.5

Maximum drawbar pull (Forward)

kN {kg}

288.3 {29,400}

Maximum drawbar pull (Reverse)

kN {kg}

256.4 {26,150}

Gradeability

deg.

25

Min. turning radius (Center of outside tire)

mm

6,430

Turning radius (BOC tip)

mm

7,650 (with BOC)

Overall length

mm

9,815 (with BOC)

Overall width

mm

3,190

Bucket width

mm

3,400 (with BOC)

Overall height (ROPS at cab top)

mm

3,785

Overall height with bucket lifted up

mm

6,430

Wheelbase

mm

3,780

Tread

mm

2,400

Minimum ground clearance

mm

450

Max. hinge pin height of bucket

mm

4,755

Dumping clearance

mm

3,295 (with BOC)

Dumping reach

mm

1,500 (with BOC)

Bucket tilt-forward angle

deg.

46

Bucket tilt-back angle (Operating posture)

deg.

50

Digging depth (Approx. 10°)

mm

435

Rated load

a

55001 and up

Operating weight

BOC: Abbreviation for Bolt-On Cutting edge.

WA500-6

3

SEN00703-01

01 Specification

Machine model name

WA500-6

Serial number

55001 and up

Model name

SAA6D140E-5 4-cycle, water-cooled, direct injection type with turbocharger, air-cooled aftercooler and water-cooled EGR

Type Number of cylinders â&#x20AC;&#x201C; Bore x Stroke

mm

6 â&#x20AC;&#x201C; 140 x 165

l {cc}

15.2 {15,240}

Flywheel horsepower

kW/rpm {HP/rpm}

263/1,900 {353/1,900}

Max. torque

Nm/rpm {kgm/rpm}

178.9/1,250 {182.4/1,250}

g/kWh {g/HPh}

216.2 {161}

Max. speed at no load

rpm

2,150

Min. speed at no load

rpm

675

Performance

Engine

Total piston displacement

Rated fuel consumption

Starting motor

24 V, 11 kW

Alternator

24 V, 75 A

Battery

12 V, 170 Ah x 2

Axle

Power train

Torque converter

3-element, 1-stage, 2-phase

Transmission

Planetary type, multi-disc type, forward-reverse 4-stage

Reduction gear unit

Spiral bevel gear type, splash lubrication type

Differential

Straight bevel gear type

Final drive

Planetary gear single reduction type, splash lubrication type

Drive wheel

Front and rear wheel drive

Front axle

Fixed frame, full-float type

Rear axle

Center pin support type, full-float type

Brake

Tires

Size Rim size Inflation pressure (Front wheel) (Rear wheel) Foot brake

25.00 x 25WTB kPa {kg/cm2}

440 {4.5} 392 {4.0} Independent front and rear wheel brakes, enclosed wet multi-disc type Full hydraulic type

Hand brake

4

29.5-25-33-22PR(L3)

Drive shaft braking system of wet disc type Hydraulically released spring-driven type

WA500-6

SEN00703-01

Machine model name

WA500-6

Serial number

55001 –

Steering system Type

Articulated steering

Structure Cylinder Control valve Hydraulic pump delivery

Hydraulic system

steering system

01 Specification

Fully-hydraulic power steering

Work equipment hydraulic pump

l/min

321 (Variable displacement piston pump HPV190)

Steering pump

l/min

120 (Variable displacement piston pump LPV90)

Cooling fan pump

l/min

70 (Variable displacement piston pump LPV45)

Power train pump

l/min

189 (Gear pump SAR (3) 112)

Hydraulic cooling pump

l/min

94 (Gear pump SAL (3) 80)

EPC and brake pump

l/min

54 (Gear pump SAR (1) 28)

Set pressure for work equipment

MPa {kg/cm2}

3-spool type (with HI valve) 34.3 {350}

Set pressure for steering system

MPa {kg/cm2}

Spool type 24.5 {250}

mm

Double-acting piston type 2 – 160 x 898

Number of lift cylinders – Bore x Stroke Number of bucket cylinders – Bore x Stroke

mm

Double-acting piston type 1 – 185 x 675

Number of steering cylinders – Bore x Stroke

mm

Double-acting piston type 2 – 100 x 486

Motor Work equipment

Fan motor

Fixed displacement piston type: LMF40

Work equipment Type of link Shape of bucket cutting edge

WA500-6

Single link Straight bolt on cutting edge

5

SEN00703-01

01 Specification

Weight table k

1

This weight table is prepared for your reference when handling or transporting the components.

Unit: kg Machine model name

WA500-6

Serial number

55001 and up

Engine (dry weight) Radiator (including air conditioner condenser) (dry weight) Torque converter (including drive gear) (dry weight) Transmission (dry weight)

1,700 326 558 1,106

Center drive shaft

45

Front drive shaft

45

Rear drive shaft

40

Center support

42

Front axle

2,250

Rear axle

2,084

Front differential

368

Rear differential

390

Planetary carrier assembly (1 piece)

69

Wheel hub (1 piece)

114

Axle pivot (front)

104

Axle pivot (rear)

126

Wheel (1 piece)

267

Tire (standard: 29.5-25-22PR L3) (1 piece)

532

Steering demand valve

24

Steering cylinder (1 piece)

53

Hydraulic tank (dry weight)

412

Work equipment hydraulic pump

106

Power train, EPC pump

22

Steering pump

39

Hydraulic cooling pump

13

Cooling fan pump

25

Torque converter oil cooler

70

Fan motor

13.4

Fan

29.1

6

WA500-6

01 Specification

SEN00703-01

Unit: kg Machine model name

WA500-6

Serial number

55001 and up

Work equipment valve

110

Lift cylinder (1 piece)

282

Bucket cylinder

289

Engine hood

265

Radiator guard

355

Front frame

2,565

Rear frame

2,650

Bucket link (including bushing)

157

Bell crank (including bushing)

754

Lift arm (including bushing) 3

2,105

Bucket (5.2 m with teeth and segment edge)

2,960

Bucket (5.6 m3 with bolt-on cutting edge)

3,005

Counterweight

2,480

Fuel tank

220

Battery (1 piece)

56

Cab (including console box and dashboard)

987

Air conditioner unit

33

Operator seat

36

WA500-6

7

SEN00703-01

01 Specification

Table of fuel, coolant and lubricants

1

a

For details of notes (Note 1, No. 2 ...) in the table, see Operation and Maintenance Manual.

q

ASTM: American Society of Testing and Material Supply points

Capacity

Engine oil pan

Transmission case

Hydraulic system

Front axle

Rear axle

Cooling system

Fuel tank

Specified capacity

(l)

45

95

460

87

81

120

473

Refill capacity

(l)

45 (37)

76

337

87

81

â&#x20AC;&#x201D;

â&#x20AC;&#x201D;

Value in ( ) applies to oil level of engine oil pan alone.

8

WA500-6

01 Specification

WA500-6

SEN00703-01

9

SEN00703-01

WA500-6 GALEO Wheel loader Form No. SEN00703-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

10

SEN00704-00

WHEEL LOADER 1SHOP MANUAL

WA500-6

Machine model

Serial number

WA500-6

55001 and up

10 Structure, function and maintenance standard

1

Engine and cooling system Engine and cooling system ............................................................................................................................. 2 Cooling system..................................................................................................................................... 2 Engine mount and transmission mount................................................................................................ 5

WA500-6

1

SEN00704-00

10 Structure, function and maintenance standard

Engine and cooling system Cooling system

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

2

Radiator Aftercooler Hydraulic oil cooler Coolant sub-tank Coolant level sensor Torque converter oil cooler Air conditioner Cooling fan Cooling fan motor Fan guard

1 1

A: B: C: D: E: F: G:

Aftercooler outlet Coolant inlet Coolant inlet Aftercooler inlet Hydraulic oil cooler outlet Hydraulic oil cooler inlet Coolant outlet

WA500-6

10 Structure, function and maintenance standard

SEN00704-00

Specifications Radiator

Hydraulic oil cooler (1)

Hydraulic oil cooler (2)

Aftercooler

Torque converter oil cooler

Aluminum tube in 4-column

PTO-OL

PTO-OL

Straight fin 10-hole tube type

PTO-LS

Fin pitch (mm)

4.0/2P

100 × 385 × 17

100 × 558 × 17

6.0/2P

150 × 620 × 20-stage

Total heat dissipation surface (m2)

59.90

1.2187

1.829

21.57

3.254

Cross sectional area of flow (cm2)

50.845

—

—

—

—

Pressure valve cracking pressure (kPa {kg/cm2})

70 ± 15

—

—

—

—

Vacuum valve cracking pressure (kPa {kg/cm2})

0–5

—

—

—

—

Core type

WA500-6

3

SEN00704-00

4

10 Structure, function and maintenance standard

WA500-6

10 Structure, function and maintenance standard

SEN00704-00

Engine mount and transmission mount

1

Unit: mm No

Check item

Criteria

1

Shim thickness of mount

Shim thickness: 0.5 mm, 1.0 mm (Shim thickness and number of shims used shall be the same as that employed on the actual machine.)

2

Clearance between stopper and support

A clearance of 1.5 mm minimum shall be provided between the stopper and support.

3

Shim thickness of mount

Shim thickness: 0.5 mm, 1.0 mm (Shim thickness and number of shims used shall be the same as that employed on the actual machine.)

4

Clearance between stopper bolt and bracket

A clearance of 1 to 1.5 mm minimum shall be provided between the stopper and bracket.

WA500-6

Remedy

Adjust

5

SEN00704-00

WA500-6 Wheel loader Form No. SEN00704-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 03-06 (01)

6

SEN00705-01

WHEEL LOADER 1SHOP MANUAL

WA500-6

Machine model

Serial number

WA500-6

55001 and up

10 Structure, function and maintenance standard

1

Power train, Part 1 Power train, Part 1 .......................................................................................................................................... 3 Power train ........................................................................................................................................... 3 Power train system diagram................................................................................................................. 4 Joint...................................................................................................................................................... 6 Drive shaft ............................................................................................................................................ 7 Power train piping diagram .................................................................................................................. 8 Torque converter ................................................................................................................................ 10 Torque converter regulator valve........................................................................................................ 28 Transmission ...................................................................................................................................... 30 Transfer .............................................................................................................................................. 50 Transmission control valve................................................................................................................. 52 ECMV................................................................................................................................................. 56 Main relief valve and torque converter relief valve............................................................................. 63

WA500-6

1

SEN00705-01

10 Structure, function and maintenance standard

Lubrication relief valve........................................................................................................................ 65

2

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Power train, Part 1 Power train

1 1

Outline q The power from engine (1) is transmitted to torque converter (2) through the flywheel and ring gear. Torque converter (2) converts the transmitted toque according to the fluctuation of the load by using oil as a medium and then transmits the power to the input shaft of transmission (3).

The engine power is also transmitted through the pump drive gear (PTO) of torque converter (2) to steering pump (4), torque converter charging pump (5), EPC pump (6), cooling pump (7), work equipment pump (8) and fan pump (9) to drive these pumps. q Transmission (3) operates 6 hydraulic clutches through the solenoid valve-based operation of the directional spool and gearshift spool to select one of 4 gear speeds in the forward or reverse travel direction.

Selection of a speed is done by use of the electrically controlled switch.

WA500-6

q

q

q

Multi-disc type parking brake (10) is installed on transmission. The power from the front side output shaft is transmitted through center drive shaft (11) and front drive shaft (13) to front differential (14). On the rear side, the power is transmitted to rear differential (19) from rear drive shaft (18).

The power being transmitted to front differential (14) and rear differential (19) is then transmitted to the axle shaft.

The power from the axle shaft is reduced in speed by final drives (15) and (20) and then transmitted to tires (17) and (22) through the planetary carrier.

3

SEN00705-01

10 Structure, function and maintenance standard

Power train system diagram

1

Without lockup clutch

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

4

Engine Torque converter Transmission Steering pump Torque converter charging pump EPC and brake pump Hydraulic cooling pump Work equipment pump Cooling fan pump Parking brake Center drive shaft

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Center support Front drive shaft Front differential Front final drive Wet-type multi-disc brake Front tire Rear drive shaft Rear differential Rear final drive Wet-type multi-disc brake Rear tire

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

With lockup clutch

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Engine Torque converter Transmission Steering pump Torque converter charging pump EPC and brake pump Hydraulic cooling pump Work equipment pump Cooling fan pump Parking brake Center drive shaft Center support

WA500-6

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

Front drive shaft Front differential Front final drive Wet-type multi-disc brake Front tire Rear drive shaft Rear differential Rear final drive Wet-type multi-disc brake Rear tire Lockup clutch (if equipped)

5

SEN00705-01

10 Structure, function and maintenance standard

Joint

1.

1

Ring gear Unit: mm

No. 2

Check item Backlash of engine side drive gear and torque converter case gear

Criteria

Remedy

0.059 â&#x20AC;&#x201C; 0.240

Replace

Outline q The ring gear is installed to the flywheel of the engine.

The internal teeth of the ring gear are meshed with the external teeth of the torque converter lockup clutch housing to transmit the power from the engine to the torque converter.

6

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Drive shaft

1.

2.

3.

4.

Front drive shaft Center support Center drive shaft Rear drive shaft

WA500-6

1

Outline The power from the engine is transmitted through the torque converter, transmission and transfer. From the transfer, part of the power is then transmitted to the rear axle through rear drive shaft (4). And the remaining portion of the power is transmitted to the front axle through center drive shaft (3), center support (2) and front drive shaft (1). q The drive shafts have the following purpose besides simple power transmission. q When the positions of the transmission and front and rear axles change because of the traveling impacts or working impacts during articulation or travel of the machine, the drive shaft absorbs the fluctuations in the angle and length by use of the universal joint and slip joint so that the power may be transmitted without damaging the parts. q

7

SEN00705-01

Power train piping diagram

1.

2.

3.

4.

5.

6.

8

10 Structure, function and maintenance standard

1

Transmission Torque converter Transmission control valve Power train pump Torque converter oil cooler Torque converter oil filter

WA500-6

10 Structure, function and maintenance standard

WA500-6

SEN00705-01

9

SEN00705-01

Torque converter

10 Structure, function and maintenance standard

1

Without lockup clutch (Torque converter, PTO, and input transfer)

10

WA500-6

10 Structure, function and maintenance standard

A: B: C: D:

From main relief valve From transmission control valve Torque converter outlet oil pressure pickup port To transfer case

1.

Hydraulic and brake cooling pump (if equipped) mounting port Cooling fan pump mounting port Transmission input shaft speed sensor Input transfer Torque converter and PTO Work equipment hydraulic pump mounting port Steering pump, power train pump and EPC brake pump mounting port Torque converter regulator valve

2.

3.

4.

5.

6.

7.

8.

SEN00705-01

Specifications Type Stall torque ratio

WA500-6

3-element, 1-stage, 1-phase 2.84

11

SEN00705-01

1.

2.

3.

4.

5.

6.

7.

8.

12

Flywheel Pilot Drive case Turbine Stator Pump PTO idler gear (Number of teeth: 51) Stator shaft

10 Structure, function and maintenance standard

9.

10.

11.

12.

13.

14.

15.

Torque converter output shaft Input transfer drive gear (Number of teeth: 59) Transmission input shaft Input transfer driven gear (Number of teeth: 47) PTO drive gear (Number of teeth: 88) Spacer Boss

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Unit: mm No.

Check item

Criteria

1

Backlash between PTO idler gear and PTO gear A

0.192 – 0.492

2

Backlash between PTO idler gear and PTO gear B

0.192 – 0.492 Standard size

3

4

5

6

7.

8.

Tolerance for fitness of bearing in PTO gear A (Small)

Tolerance for fitness of bearing in PTO gear A (Large) Tolerance for fitness of bearing in PTO gear B (Small) Tolerance for fitness of bearing in PTO gear B (Large)

Remedy

Tolerance Shaft

Hole

Outside diameter

100

–0.000 –0.015

–0.010 –0.045

Inside diameter

55

+0.030 +0.011

–0.000 –0.015

Outside diameter

150

–0.000 –0.018

+0.026 –0.014

Inside diameter

85

+0.035 +0.013

–0.000 –0.020

Outside diameter

100

–0.000 –0.015

–0.010 –0.045

Inside diameter

55

+0.030 +0.011

–0.000 –0.015

Outside diameter

125

–0.000 –0.018

+0.026 –0.014

Inside diameter

70

+0.030 +0.011

–0.000 –0.015

Replace

PTO gear A (Number of teeth: 84) PTO gear B (Number of teeth: 84)

WA500-6

13

SEN00705-01

14

10 Structure, function and maintenance standard

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Unit: mm No. 1

2

3

Check item

Criteria Tolerance

Repair limit

80

–0.040 –0.070

79.92

Inside diameter of sleeve seal ring contact surface

65

+0.030 –0.000

65.1

Width

3

–0.01 –0.03

2.7

Thickness

2.7

±0.1

2.55

170

+0.040 –0.000

170.5

Outside diameter of pilot

Wear of output shaft seal ring

Inside diameter of PTO drive gear seal ring contact surface

5

6

7

Tolerance for fitness of PTO idler gear bearing

Shaft

Hole

125

–0.000 –0.020

–0.028 –0.068

Inside diameter

70

+0.012 –0.007

–0.000 –0.015

150

–0.000 –0.020

–0.012 –0.052

85

+0.059 +0.037

–0.000 –0.020

140

–0.000 –0.020

–0.012 –0.052

80

+0.051 +0.032

–0.000 –0.015

Outside diameter

125

–0.000 –0.020

–0.012 –0.052

Inside diameter

80

+0.051 +0.032

–0.000 –0.015

Outside Tolerance for fitness diameter of input transfer drive Inside gear bearing (Small) diameter Tolerance for fitness of input transfer driven gear bearing

Replace

Outside diameter

Outside Tolerance for fitness diameter of input transfer drive Inside gear bearing (Large) diameter

8

Backlash between PTO drive gear and PTO idler gear

0.192 – 0.492

9

Backlash between input transfer drive gear and driven gear

0.190 – 0.486

10

Clearance between cage and case of input transfer drive gear

Clearance between cage and 11 case of input transfer driven gear

WA500-6

Repair by hard chromium-plating or replace

Repair by hard chromium-plating or replace

Tolerance

Standard size 4

Remedy

Standard size

Standard clearance

Clearance limit

0.40 – 1.60 (Standard shim thickness: 1.0)

—

0.60 – 1.80 (Standard shim thickness: 1.0)

—

Replace

15

SEN00705-01

10 Structure, function and maintenance standard

Power transmitting route

q q q

q

q

16

The power from engine is transmitted to drive case (2) through flywheel (1).

The power being transmitted to drive case (2) rotates pump (3) and PTO drive gear (4).

The power being transmitted to pump (3) rotates turbine (6) and boss (7) using oil as the medium, and then transmitted to output shaft (8).

The power being transmitted to output shaft (8) is then transmitted to transmission input shaft (11) through drive gear (9) and driven gear (10).

The power being transmitted to PTO drive gear (4) is then transmitted through PTO idler gear (5) and PTO gear and then used as the pump driving power.

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Oil flow

q

q

q

The oil flows to the torque converter relief valve through the main relief valve and there its pressure is regulated to below the set pressure by the valve. The oil flows to pump (4) through inlet port (A) and oil passage of case (1), stator shaft (2) and spacer (3).

The oil is given a centrifugal force by pump (4), and then it enters turbine (5) to transmit its energy to turbine (5).

The oil from turbine (5) is sent to stator (6), and then returned to pump (4). Part of this oil is sent to the oil cooler through stator (6), oil passage of stator shaft (2), outlet port (B) and torque converter regulator valve.

WA500-6

17

SEN00705-01

10 Structure, function and maintenance standard

With lockup clutch (Torque converter, PTO, and input transfer)

18

WA500-6

10 Structure, function and maintenance standard

A: B: C: D: E:

From main relief valve From lockup clutch ECMV From transmission control valve Torque converter outlet oil pressure pickup port To transfer case

1.

Hydraulic and brake cooling pump (if equipped) mounting port Cooling fan pump mounting port Transmission input shaft speed sensor Input transfer Torque converter and PTO Work equipment hydraulic pump mounting port Steering, power train and PPC pump mounting port Torque converter regulator valve

2.

3.

4.

5.

6.

7.

8.

SEN00705-01

Specifications Type Stall torque ratio

WA500-6

3-element, 1-stage, 2-phase 2.73

19

SEN00705-01

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

20

Flywheel Pilot Lockup clutch housing Turbine Stator Drive case Pump PTO idler gear (Number of teeth: 51) Stator shaft Torque converter output shaft

10 Structure, function and maintenance standard

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Input transfer drive gear (Number of teeth: 59) Transmission input shaft Input transfer driven gear (Number of teeth: 47) PTO drive gear (Number of teeth: 88) Spacer Free wheel Race Lockup clutch disc Lockup clutch piston Boss

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Unit: mm No.

Check item

Criteria

1

Backlash between PTO idler gear and PTO gear A

0.192 – 0.492

2

Backlash between PTO idler gear and PTO gear B

0.192 – 0.492 Standard size

3

4

5

6

7.

8.

Tolerance for fitness of bearing in PTO gear A (Small)

Tolerance for fitness of bearing in PTO gear A (Large) Tolerance for fitness of bearing in PTO gear B (Small) Tolerance for fitness of bearing in PTO gear B (Large)

Remedy

Tolerance Shaft

Hole

Outside diameter

100

–0.000 –0.015

–0.010 –0.045

Inside diameter

55

+0.030 +0.011

–0.000 –0.015

Outside diameter

150

–0.000 –0.018

+0.026 –0.014

Inside diameter

85

+0.035 +0.013

–0.000 –0.020

Outside diameter

100

–0.000 –0.015

–0.010 –0.045

Inside diameter

55

+0.030 +0.011

–0.000 –0.015

Outside diameter

125

–0.000 –0.018

+0.026 –0.014

Inside diameter

70

+0.030 +0.011

–0.000 –0.015

Replace

PTO gear A (Number of teeth: 84) PTO gear B (Number of teeth: 84)

WA500-6

21

SEN00705-01

22

10 Structure, function and maintenance standard

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Unit: mm No. 1

Check item

Criteria Standard size

Tolerance

Repair limit

80

–0.040 –0.070

79.92

40

+0.025 –0.000

40.1

Width

3

–0.01 –0.03

2.7

Thickness

1.7

±0.1

1.55

65

+0.030 –0.000

65.1

Width

3

–0.01 –0.03

2.7

Thickness

2.7

±0.1

2.55

Outside diameter of pilot Inside diameter of pilot seal ring contact surface

2

Wear of output shaft seal ring

Inside diameter of stator shaft seal ring contact surface 3 Wear of output shaft seal ring

Remedy

4

Inside diameter of PTO drive gear seal ring contact surface

170

+0.040 –0.000

170.5

5

Inside diameter of race free wheel transfer surface

102.555

±0.008

102.585

6

Inside diameter of stator shaft free wheel transfer surface

83.6

+0.004 –0.009

83.57

7

Inside diameter of sliding portion of bushing

83.71

+0.015 –0.000

83.79

8

Thickness of sliding portion of bushing

6

±0.05

5.5

9

Thickness of clutch disc

5.4

±0.1

Standard size Tolerance for fitness of 10 PTO idler gear bearing

11

Tolerance for fitness of input transfer drive gear bearing (Large)

Tolerance for fitness of 12 input transfer drive gear bearing (Small) Tolerance for fitness of 13 input transfer driven gear bearing

Repair by hard chromium-plating or replace Replace Repair by hard chromium-plating or replace

4.9

Shaft

Hole

125

–0.028 –0.068

Inside diameter

70

+0.012 –0.007

–0.000 –0.015

Outside diameter

150

–0.000 –0.020

–0.012 –0.052

Inside diameter

85

+0.059 +0.037

–0.000 –0.020

Outside diameter

140

–0.000 –0.020

–0.012 –0.052

Inside diameter

80

+0.051 +0.032

–0.000 –0.015

Outside diameter

125

–0.000 –0.020

–0.012 –0.052

Inside diameter

80

+0.051 +0.032

–0.000 –0.015

14

Backlash between PTO drive gear and PTO idler gear

0.192 – 0.492

15

Backlash between input transfer drive gear and driven gear

0.190 – 0.486

16

Clearance between cage and case of input transfer drive gear

17

Clearance between cage and case of input transfer driven gear

WA500-6

Replace

Tolerance –0.000 –0.020

Outside diameter

Repair by hard chromium-plating or replace

Standard clearance

Clearance limit

0.40 – 1.60 (Standard shim thickness: 1.0)

—

0.60 – 1.80 (Standard shim thickness: 1.0)

—

Replace

23

SEN00705-01

10 Structure, function and maintenance standard

Power transmitting route When lockup clutch is â&#x20AC;&#x153;disengagedâ&#x20AC;?

Drive case (3) is disconnected from boss (9) and turbine (8) and lockup torque converter works as an ordinary torque converter.

The power from engine O Flywheel (1) O Clutch housing (2), drive case (3), pump (5) and PTO drive gear (6) rotate together O Oil is used as medium O Turbine (8) and boss (9) O (To right top) o q

24

o (from left bottom) O Output shaft (10) O Drive gear (11) O Driven gear (12) O Transmission input shaft (13)

The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and PTO gear and then used as the pump driving power.

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

When lockup clutch is â&#x20AC;&#x153;engagedâ&#x20AC;?

Drive case (3) is connected to boss (9) and turbine (8) and lockup torque converter is locked up.

The power from engine O Flywheel (1) O Clutch housing (2), drive case (3), pump (5) and PTO drive gear (6) rotate together O Lockup clutch (4) O Boss (9) O (To right top) o q

o (from left bottom) O Output shaft (10) O Drive gear (11) O Driven gear (12) O Transmission input shaft (13)

The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and PTO gear and then used as the pump driving power.

WA500-6

25

SEN00705-01

10 Structure, function and maintenance standard

Oil flow

q

q

q

26

The oil flows to the torque converter relief valve through the main relief valve and there its pressure is regulated to below the set pressure by the valve. The oil flows to pump (4) through inlet port (A) and oil passage of case (1), stator shaft (2) and spacer (3).

The oil is given a centrifugal force by pump (4), and then it enters turbine (5) to transmit its energy to turbine (5).

The oil from turbine (5) is sent to stator (6), and then returned to pump (4). Part of this oil is sent to the oil cooler through stator (6), oil passage of stator shaft (2), outlet port (B) and torque converter regulator valve.

WA500-6

10 Structure, function and maintenance standard

WA500-6

SEN00705-01

27

SEN00705-01

10 Structure, function and maintenance standard

Torque converter regulator valve

1

Unit: mm No.

1

Check item Clearance between spool and valve body

Criteria Standard size 32

Tolerance Shaft

Hole

Standard clearance

Clearance limit

–0.050 –0.066

+0.025 +0.000

0.050 – 0.091

0.111

Standard size 2

Valve spring

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

126.6

106.5

205 N {20.9 kg}

122.8

195 N {19.9 kg}

3.

4.

Spool Valve body

A: B: C: D:

From torque converter To oil cooler Drain Torque converter outlet port oil pressure pickup port

28

Remedy

Replace

Outline q This valve is provided at the torque converter outlet circuit in order to secure an optimum performance of the torque converter by adjusting its set oil pressure.

Set pressure: 0.42 ± 0.05 MPa {4.3 ± 0.5 kg/cm2}

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Operation

q q

q

The oil from the torque converter is conducted to chamber (D) through port (A) and orifice (a).

When the oil pressure force generated in chamber (D) is smaller than the tension of spring (1), spool (2) is pressed leftward, closing port (A) and port (B).

If the oil pressure force generated in chamber (D) becomes larger than the tension of spring (1), spool (2) is pressed rightward, opening port (A) and port (B).

WA500-6

29

SEN00705-01

Transmission

10 Structure, function and maintenance standard

1

(Transmission, transfer and parking brake) a Transmission with lockup clutch

30

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

To torque converter To parking brake emergency release valve To lockup clutch (if equipped) To parking brake emergency release valve (To parking brake) E: From oil cooler F: From power train pump G: From parking brake emergency release valve H: To input transfer lubrication J: Parking brake oil pressure pickup port K: From main relief valve L: From lockup clutch ECMV (if equipped)

M: N: P: R: S: T: U: V: W: X: Y:

From F clutch ECMV (to F clutch) To 4th clutch From R clutch ECMV (to R clutch) From 3rd clutch ECMV (to 3rd clutch) To 2nd clutch To transmission and transfer lubrication From lubrication relief valve From 2nd clutch ECMV From 4th clutch ECMV To 1st clutch From 1st clutch ECMV

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Transmission control valve Torque converter drain tube mounting port Drain valve Drain plug Transmission lubricant temperature sensor Strainer

A: B: C: D:

Transfer Parking brake Transmission Emergency steering pump mounting port Oil filler tube mounting port Speed sensor Lubrication relief valve

WA500-6

31

SEN00705-01

32

10 Structure, function and maintenance standard

WA500-6

10 Structure, function and maintenance standard

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

Transmission input shaft Tie bolt R ring gear (Hub) R planetary pinion (Number of teeth: 24) R ring gear (Number of inside teeth: 70) F planetary pinion (Number of teeth: 23) F ring gear (Number of inside teeth: 75) 4th ring gear (Number of inside teeth: 73) 4th planetary pinion (Number of teeth: 28) 3rd planetary pinion (Number of teeth: 20) 3rd ring gear (Number of inside teeth: 76) 2nd ring gear (Number of inside teeth: 76) 2nd planetary pinion (Number of teeth: 20) 1st hub Transmission output shaft (4th sun gear) (Number of teeth: 17) Transfer input gear (Number of teeth: 50) 2nd sun gear (Number of teeth: 36) 1st clutch housing 1st clutch piston 2nd carrier 3rd sun gear (Number of teeth: 36) 1st piston return spring 2nd clutch housing 2nd piston return spring 2nd clutch piston 2nd clutch housing 3rd and 4th carriers 3rd piston return spring 3rd clutch piston 3rd and 4th clutch housings 4th clutch piston 4th piston return spring F and 4th clutch cages F piston return spring F sun gear (Number of teeth: 29) F carrier F clutch piston R and F clutch housings R clutch piston Washer spring R piston return spring R carrier Clutch disc Clutch plate R clutch cage R sun gear (Number of teeth: 22)

WA500-6

SEN00705-01

Outline q The transmission employed consists of the united planetary gear mechanism and disc clutch that provides “4 forward gear speeds and 4 reverse gear speeds”. q The transmission selects a single rotating direction and a single gear speed by fixing the planetary gear mechanism and 2 of 6 disc clutches by use of ECMV. q The transmission transmits the power being transmitted to the transmission input shaft to the output shaft after selecting a single speed from the 1st to 4th speeds both in the forward and reverse travel. In this case, the gear speed change is done by F and R clutches plus combinations of 4 speed clutches.

Number of plates and disc used Clutch No.

Number of plates

Number of discs

R clutch

6

7

F clutch

6

7

4th clutch

3+2

4

3rd clutch

2+2

3

2nd clutch

2+1

3

1st clutch

3+2

4

Combinations of clutches at respective gear speeds and reduction ratio Gear speed

Clutch used Reduction ratio

Forward 1st speed

F x 1st

3.586

Forward 2nd speed

F x 2nd

1.935

Forward 3rd speed

F x 3rd

1.153

Forward 4th speed

F x 4th

0.677

Neutral

—

—

Reverse 1st speed

R x 1st

3.182

Reverse 2nd speed

R x 2nd

1.717

Reverse 3rd speed

R x 3rd

1.023

Reverse 4th speed

R x 4th

0.601

33

SEN00705-01

1.

2.

3.

4.

5.

6.

34

10 Structure, function and maintenance standard

Transfer idler gear (Number of teeth: 71) Transfer output gear (Number of teeth: 72) Output shaft Front coupling Rear coupling Parking brake

WA500-6

10 Structure, function and maintenance standard

WA500-6

SEN00705-01

35

SEN00705-01

10 Structure, function and maintenance standard

Unit: mm No.

Check item

Criteria Standard size

1

R clutch spring (10 springs)

Remedy Repair limit

Free length

Installed length

77

70.2

48.1 N {4.9 kg}

72.4

41.2 N {4.2 kg}

77

71.7

37.3 N {3.8 kg}

72.4

31.4 N {3.2 kg}

Installed load Free length Installed load

2

F clutch spring (10 springs)

3

4th clutch spring (10 springs)

48.5

44.2

59.8 N {6.1 kg}

45.6

51.0 N {5.2 kg}

4

3rd clutch spring (10 springs)

39.8

33

94.1 N {9.6 kg}

37.4

80.4 N {8.2 kg}

5

2nd clutch spring (10 springs)

39.8

34.9

67.7 N {6.9 kg}

37.4

57.9 N {5.9 kg}

6

1st clutch spring (10 springs)

46

39

110 N {11.2 kg}

43.2

93.2 N {9.5 kg}

7

Total assembled thickness of 7 discs and 6 plates for R clutch

8

Total assembled thickness of 7 discs and 6 plates for F clutch

9

Standard size

Tolerance

Repair limit

54.2

±0.36

50.5

54.2

±0.36

50.5

Total assembled thickness of 4 discs and 5 plates for 4th clutch

45.0

±0.30

41.8

10

Total assembled thickness of 3 discs and 4 plates for 3rd clutch

35.0

±0.26

32.6

11

Total assembled thickness of 3 discs and 3 plates for 2nd clutch

26.4

±0.24

24.8

12

Total assembled thickness of 4 discs and 5 plates for 1st clutch

45.0

±0.30

41.8

R, F, 2nd

5.0

±0.1

4.5

4th, 3rd, 1st

5.0

±0.1

4.2

R, F

3.2

±0.1

2.9

4th, 3rd, 1st

5.0

±0.1

4.5

3.2

±0.1

2.9

5.0

±0.1

4.5

Width

4.5

–0.01 –0.03

4.05

Thickness

5.2

±0.12

5.05

Width

4.0

–0.01 –0.03

3.60

Thickness

5.0

±0.15

4.85

Width

4.0

–0.01 –0.04

3.60

Thickness

5.0

±0.15

4.85

Width

4.0

–0.01 –0.04

3.60

Thickness

5.0

±0.15

4.85

Width

3.0

–0.01 –0.03

2.70

Thickness

3.3

±0.1

3.15

13 Thickness of clutch disc

14

Thickness of clutch plate

2nd

15

16

17

18

19

36

Wear of R spacer seal ring Wear of R clutch cage seal ring Wear of F clutch cage seal ring Wear of seal ring of 3rd and 4th carrier Wear of 3rd spacer seal ring

Replace

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Unit: mm No.

Check item

Wear of 1st clutch cage 20 seal ring

21

22

Wear of output shaft seal ring Wear of output shaft seal ring

Backlash between sun 23 gear and planetary pinion Backlash between out24 put shaft and planetary pinion Backlash between plan25 etary pinion and ring gear 26

Criteria Standard size

Tolerance

Repair limit

4.5

–0.01 –0.03

4.05

Thickness

5.8

±0.15

5.65

Width

3.0

–0.01 –0.03

2.70

Thickness

3.1

±0.1

2.95

Width

2.5

–0.01 –0.03

2.25

Thickness

1.7

±0.1

1.55

Width

R, F

0.13 – 0.32

3rd, 2nd

0.12 – 0.33

4th

0.11 – 0.30

R, F

0.15 – 0.38

4th, 3rd, 2nd

0.13 – 0.36

Backlash between transfer input gear and idler gear

Tolerance for fitness of 27 transfer input gear bear- Outside diameter ing (Rear) Inside diameter Outside Tolerance for fitness of diameter 28 transfer input gear bearInside ing (Front) diameter 29 Clearance between cage and case

Replace

0.19 – 0.48 Tolerance

Standard size

WA500-6

Remedy

Shaft

Hole

160

0 –0.025

–0.012 –0.052

90

+0.045 +0.023

0 –0.020

160

0 –0.025

0 –0.040

90

+0.045 +0.023

0 –0.020

Standard clearance

Clearance limit

1.61 – 2.39 (Standard shim thickness: 2.0)

—

37

SEN00705-01

38

10 Structure, function and maintenance standard

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Unit: mm No.

Check item

Criteria

1

Outside diameter of coupling oil seal contact surface (Rear)

2

Outside diameter of coupling oil seal contact surface (Front)

3

Backlash between idler gear and output gear

Standard size

Tolerance

Repair limit

105

–0.000 –0.087

104.8

105

–0.000 –0.087

104.8

4

5

6

Tolerance for fitness of output shaft bearing (Rear) Tolerance for fitness of output gear bearing (Front)

Shaft

Hole

180

–0.000 –0.025

–0.000 –0.040

Inside diameter

100

+0.059 +0.037

–0.000 –0.020

Outside diameter

190

–0.000 –0.030

–0.014 –0.060

Inside diameter

105

+0.059 +0.037

–0.000 –0.020

Outside diameter

150

–0.000 –0.020

–0.020 –0.040

Inside diameter

85

+0.045 +0.023

–0.000 –0.020

Clearance between cage and case

8

Clearance between cover and cage

WA500-6

Tolerance

Outside diameter

7

Repair by hard chromium-plating or replace

0.19 – 0.48 Standard size

Tolerance for fitness of idler gear bearing

Remedy

Standard clearance

Clearance limit

0.63 – 1.37 (Standard shim thickness: 1.0)

—

0.48 – 1.32 (Standard shim thickness: 0.5)

—

Replace

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10 Structure, function and maintenance standard

Disc clutch Structure

q

q q

Disc clutch is used for fixing ring gear (1). It consists of piston (2), plate (3), disc (4), pin (5), return spring (6) and washer (8).

Inside teeth of disc (4) are engaged with outside teeth of ring gear (1).

Plate (3) is assembled to clutch housing (7) with pin (5).

Operation When clutch is “engaged” (fixed)

q

q

q

The oil from ECMV is sent with pressure to the rear side of piston (2) through the oil passage of housing (7) and pushes piston (2) leftward.

Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them.

Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), move of ring gear (1) is stopped.

When clutch is “disengaged” (released)

q q q

40

As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6).

The friction force between plates (3) and discs (4) is released and ring gear (1) is released.

Washer spring (8) is installed between plate (3) of the pin block and plate (3). This spring quickens return of piston (2) as the clutch is disengaged by providing smooth separation of plate (3) and disc (4). At the same time, it is used for preventing the dragging.

WA500-6

10 Structure, function and maintenance standard

WA500-6

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41

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10 Structure, function and maintenance standard

Power transmitting route Forward 1st gear speed

42

WA500-6

10 Structure, function and maintenance standard

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F ring gear (4) of F clutch and 1st hub (16) of 1st clutch are fixed hydraulically.

The power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd and 4th carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 1st clutch housing (15) O 1st hub (16) O Output shaft (23)

WA500-6

3rd sun gear (20)

43

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10 Structure, function and maintenance standard

Forward 2nd gear speed

44

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

F ring gear (4) of F clutch and 2nd ring gear (18) of 2nd clutch are fixed hydraulically.

The power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd and 4th carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (17) O 2nd sun gear (19) O Output shaft (23)

WA500-6

3rd sun gear (20)

45

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10 Structure, function and maintenance standard

Forward 3rd gear speed

F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically.

The power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd and 4th carrier (11) O 3rd planetary pinion (12) O 3rd sun gear (20) O Output shaft (23)

46

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Forward 4th gear speed

F ring gear (4) of F clutch and 4th ring gear (22) of 4th clutch are fixed hydraulically.

The power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd and 4th carrier (11) O 4th planetary pinion (21) O Output shaft (23)

WA500-6

47

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10 Structure, function and maintenance standard

Reverse 1st gear speed

48

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10 Structure, function and maintenance standard

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R ring gear (7) of R clutch and 1st hub (16) of 1st clutch are fixed hydraulically.

The power from torque converter O Input shaft (1) O R sun gear (5) O R planetary pinion (6) O 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)) O F carrier (10) O 3rd and 4th carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 1st clutch housing (15) O 1st hub (16) O Output shaft (23)

WA500-6

3rd sun gear (20)

49

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10 Structure, function and maintenance standard

Transfer

1

Outline q The transfer is installed in the output side of the transmission and fixed to the transmission case with the bolt.

Operation Power transmitting route Transmission output shaft (1) O Transfer input gear (2) O Transfer idler gear (3) O Transfer output gear (4) O Output shaft (5) O Center drive shaft O Front drive shaft O Front axle

50

Rear drive shaft O Rear axle

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10 Structure, function and maintenance standard

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51

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Transmission control valve

10 Structure, function and maintenance standard

1

Without lockup clutch

52

WA500-6

10 Structure, function and maintenance standard

A: B: C: D: E: F: G: H: J: K: L:

1st clutch oil pressure pickup port 4th clutch oil pressure pickup port 3rd clutch oil pressure pickup port F clutch oil pressure pickup port R clutch oil pressure pickup port Torque converter relief pressure pickup port Main relief oil pressure pickup port From power train pump 2nd clutch oil pressure pickup port To PTO and input transfer lubrication To parking brake emergency release valve (To parking brake) M: To parking brake emergency release valve 1.

2.

3.

4.

5.

6.

7.

1st clutch ECMV 4th clutch ECMV 3rd clutch ECMV F clutch ECMV Parking brake solenoid valve R clutch ECMV Main relief valve and torque converter relief valve 8. Last chance filter 9. 2nd clutch ECMV 10. Check valve

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Operation table of ECMV ECMV Gear speed

F

R

1st

3rd

4th

Q

Q

Q

A

N

2nd

Q

M F1

Q

F2

Q

F3

Q

F4

Q

Q

Q Q Q Q

R1

Q

R2

Q

R3

Q

R4

Q

Q Q Q Q

A: Automatic shifting M: Manual shifting

a

With the directional lever is in the N (Neutral) position during manual shifting, the speed clutch for the gear speed selected with the gear shift lever operates.

Outline q The oil from the pump flows to the transmission control valve through the oil filter. Then oil flow is divided into the main relief circuit and clutch actuation circuit. q The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then used to actuate the clutch and parking brake through the last chance filter. The oil relieved from the main relief valve is supplied to the torque converter. q When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to the command current from the transmission controller to reduce the gear shifting shocks. The ECMV also keeps the clutch pressure constant during travel. q If the F, R, or 1st â&#x20AC;&#x201C; 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to set the transmission in the desired gear speed.

WA500-6

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10 Structure, function and maintenance standard

With lockup clutch

54

WA500-6

10 Structure, function and maintenance standard

A: B: C: D: E: F: G: H: J: K: L: M: N:

1st clutch oil pressure pickup port 4th clutch oil pressure pickup port 3rd clutch oil pressure pickup port F clutch oil pressure pickup port R clutch oil pressure pickup port Torque converter relief pressure pickup port Main relief oil pressure pickup port From power train pump Lockup clutch ECMV oil pressure pickup port 2nd clutch oil pressure pickup port To PTO and input transfer lubrication To parking brake emergency release valve (To parking brake) To parking brake emergency release valve

1.

2.

3.

4.

5.

6.

7.

1st clutch ECMV 4th clutch ECMV 3rd clutch ECMV F clutch ECMV Parking brake solenoid valve R clutch ECMV Main relief valve and torque converter relief valve 8. Last chance filter 9. Lockup clutch ECMV 10. 2nd clutch ECMV 11. Check valve

SEN00705-01

Operation table of ECMV ECMV Gear speed

F

R

1st 2nd 3rd 4th L/U Q

A

N

Q

M F1

Q

F2

Q

F3

Q

F4

Q

Q

Q

Q

Q Q

Q Q

Q Q

R1

Q

R2

Q

R3

Q

R4

Q

Q

Q Q

Q Q

Q Q

Q

L/U : Lockup clutch ECMV A : Automatic shifting M : Manual shifting

a

With the directional lever is in the N (Neutral) position during manual shifting, the speed clutch for the gear speed selected with the gear shift lever operates.

Outline q The oil from the pump flows to the transmission control valve through the oil filter. Then oil flow is divided into the main relief circuit and clutch actuation circuit. q The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then used to actuate the clutch and parking brake through the last chance filter. The oil relieved from the main relief valve is supplied to the torque converter. q When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to the command current from the transmission controller to reduce the gear shifting shocks. The ECMV also keeps the clutch pressure constant during travel. q If the F, R, or 1st â&#x20AC;&#x201C; 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to set the transmission in the desired gear speed. q In the 2nd, 3rd and 4th speed travel, the lockup clutch ECMV operates at a speed higher than the speed being specified from the transmission controller.

WA500-6

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10 Structure, function and maintenance standard

ECMV a

1

ECMV: Abbreviation for Electronic Control Modulation Valve

For F, R, 1st, 2nd, 3rd, and 4th clutch a Don't try to disassemble it since adjustment for maintaining the performance will be needed.

A: P: T: Dr: P1:

To clutch From pump Drain Drain Clutch oil pressure pickup port

1.

2.

3.

4.

5.

6.

7.

Fill switch connector Proportional solenoid connector Flow rate pickup valve Fill switch Proportional solenoid Pressure control valve Nameplate (*1)

56

*1: Clutch used

Letters printed on nameplate

F, R, 1st, 2nd, 3rd, and 4th

D*******

WA500-6

10 Structure, function and maintenance standard

Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, and then converts it into oil pressure. q Fill switch This switch detects that the clutch is filled with oil and has the following functions.

1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil.

2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.

SEN00705-01

ECMV and proportional solenoid q For each ECMV, 1 proportional solenoid is installed.

The proportional solenoid generates thrust shown below according to the command current from the controller.

The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil.

Current – propulsion force characteristics of proportional solenoid

Propulsion force - Hydraulic pressure characteristics of proportional solenoid

Range A: Range B: Range C: Range D: Point E: Point F: a

Before shifting gear (When draining) During filling Pressure regulation During filling (During triggering) Start of filling Finish of filling

The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “ON” during triggering (Range D).

WA500-6

ECMV and fill switch q For each ECMV, 1 fill switch is installed.

If the clutch is filled with oil, the fill switch is turned “ON” by the pressure of the clutch. The oil pressure is built up according to this signal.

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Operation of ECMV q ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal.

The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below.

10 Structure, function and maintenance standard

Before shifting gear (when draining) (Range A in chart)

q

Range A: Range B: Range C: Range D: Point E: Point F: a

58

While no current is flowing in proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T).

At this time, since no oil pressure is applied to flow rate pickup valve (4), fill switch (5) is turned “OFF”.

Before shifting gear (When draining) During filling Pressure regulation During filling (During triggering) Start of filling Finish of filling

The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “ON” during triggering (Range D).

WA500-6

10 Structure, function and maintenance standard

During filling (Range B in chart)

q

If a current is given to proportional solenoid (1) while there is no oil in the clutch, a hydraulic force balanced with the solenoid force is applied to chamber (B) and it pushes pressure control valve (3) to the left. This conducts oil through pump port (P) and orifice (a) of flow rate pickup valve (4) to start filling the oil to the clutch chamber. At this time, differential pressure is generated between the upper stream and down stream of orifice (a) of flow rate pickup valve (4). This differential pressure pushes flow rate pickup valve (4) leftward. As the clutch chamber is filled up with oil and oil flow from pump port (P) to clutch port (A) is stopped, differential pressure before and after orifice (a) of flow rate pickup valve (4) disappears. As the result, flow rate pickup valve (4) is pushed rightward, turning â&#x20AC;&#x153;ONâ&#x20AC;? fill switch (5).

WA500-6

SEN00705-01

Pressure regulation (Range C in chart)

q

If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the repulsive force of pressure control valve spring (2), and thus the pressure is settled.

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10 Structure, function and maintenance standard

For lockup clutch a Don't try to disassemble it since adjustment for maintaining the performance will be needed.

A: P: T: Dr: P1:

To clutch From pump Drain Drain Clutch oil pressure pickup port

1.

2.

3.

4.

5.

Proportional solenoid connector Sleeve Proportional solenoid Pressure control valve Nameplate (*1)

60

*1: Clutch used

Letters printed on nameplate

Lockup

K*******

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10 Structure, function and maintenance standard

SEN00705-01

Outline ECMV for lockup clutch q This valve is used to switch the clutch in order to regulate the clutch oil pressure to the set pressure.

Since the modulation waveform is used for the pressure application characteristics to the clutch, ECMV is capable of connecting the lockup clutch smoothly, thereby reducing shocks resulting from gear shift. Above also prevents generation of peak torque in the power train. These arrangements make the machine comfortable to operator and enhance durability of the power train.

When changing from torque converter travel to direct travel

At gear shift (in direct travel)

WA500-6

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Operation When clutch is “disengaged” (released)

q

While no current is flowing in to proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T).

10 Structure, function and maintenance standard

When clutch is “engaged” (fixed)

q

q

62

As current is conducted to proportional solenoid (1), the oil pressure being balanced with the solenoid force is applied to chamber (B), pushing pressure control valve (3) leftward.

Above opens pump port (P) and clutch port (A) to start filling oil to the clutch.

As the clutch is filled with oil, the solenoid thrust is balanced with the sum of the thrust generated from oil pressure of the clutch port and the tension of the pressure control valve spring (2), and then the pressure is settled.

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Main relief valve and torque converter relief valve

1

Unit: mm No.

1

2

Check item Clearance between main relief vale and valve body Clearance between torque converter relief vale and valve body

Criteria Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

28

–0.035 –0.045

+0.013 +0.000

0.035 – 0.058

0.078

22

–0.035 –0.045

+0.013 +0.000

0.035 – 0.058

0.078

Standard size 3

Main relief valve spring (Outside)

Remedy

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

128

78.3

479.1 N {48.9 kg}

124.2

456 N {46.5 kg}

4

Main relief valve spring (Inside)

108

78.3

365.5 N {37.3 kg}

104.8

347 N {35.4 kg}

5

Torque converter relief valve spring

50

43

134.3 N {13.7 kg}

48.5

127 N {13.0 kg}

6.

7.

8.

9.

10.

Body Piston Torque converter relief valve Piston Main relief valve

WA500-6

A: B: C: D: E: P1: P2:

Replace

Drain (Torque converter relief) Drain From pump Drain To torque converter Main relief oil pressure pickup port Torque converter relief pressure pickup port

63

SEN00705-01

Outline

10 Structure, function and maintenance standard

Operation of main relief valve

Torque converter relief valve q The torque converter relief valve regulates the torque converter inlet circuit pressure below the set pressure to protect the torque converter from abnormally high pressure.

Set pressure: 0.84 MPa {8.55 kg/cm2} (Cracking pressure) Main relief valve q The main relief valve regulates the pressure in the transmission and brake hydraulic circuits below the set pressure.

Set pressure: 3.64 MPa {37.1 kg/cm2} (At rated engine speed)

q

The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief valve and orifice (a) of main relief valve (1).

q

As the oil pressure in the circuit goes beyond the set pressure, the oil conducted to chamber (F) pushes piston (2) and the resulting resisting force pushes spool (1) leftward, opening ports (C) and (E).

Above operation conducts the oil from port (E) to the torque converter.

Operation Operation of torque converter relief valve

q

q

64

The oil from the main relief valve is conducted to the torque converter through port (E) and, at the same time, also conducted to chamber (G) through orifice (b) of torque converter relief valve (3).

As the oil pressure to the torque converter goes beyond the set pressure, the oil conducted to chamber (G) pushes piston (4) and the resulting resisting force pushes torque converter relief valve (3) rightward, opening ports (E) and (A).

As the result, the oil in port (E) is drained through port (A).

WA500-6

10 Structure, function and maintenance standard

SEN00705-01

Lubrication relief valve

1

Unit: mm No.

1

Check item

Criteria Standard size

Clearance between spool and valve body

22

Tolerance Shaft

Hole

Standard clearance

Clearance limit

–0.035 –0.045

+0.013 +0.000

0.035 – 0.058

0.078

Standard size 2

Valve spring

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

59.7

37

97.4 N {9.94 kg}

57.9

92.6 N {9.44 kg}

3.

4.

Valve body Spool

A: B: C:

From oil cooler Drain Lubricant pressure pickup port

WA500-6

Remedy

Replace

Function The Lubrication relief valve is installed to the transmission valve and used for maintaining the pressure of the lubrication circuit below the set pressure.

Set pressure: 0.26 MPa {2.7 kg/cm2} (Cracking pressure)

q

65

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WA500-6 GALEO Wheel loader Form No. SEN00705-01

© 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01)

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WHEEL LOADER 1SHOP MANUAL

WA500-6

Machine model

Serial number

WA500-6

55001 and up

10 Structure, function and maintenance standard

1

Power train, Part 2 Power train, Part 2 .......................................................................................................................................... 2 Torque converter oil cooler................................................................................................................... 2 Torque converter oil filter...................................................................................................................... 3 Center support ..................................................................................................................................... 6 Axle ...................................................................................................................................................... 8 Differential .......................................................................................................................................... 10 Limited slip differential........................................................................................................................ 19 Final drive........................................................................................................................................... 24

WA500-6

1

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