Cargador - Wa-500-6 - Testeo y Ajustes

Testing & Adjusting WA500-6
Testing & Adjusting WA500-6 Page 1 (04/2006)

WA500-6
Testing & Adjusting
Engine

NOTE :
All procedures explained in “Testing &
Adjusting_WA500-6.ppt” are an extract from the
actual Shop Manual.
Please review the Shop Manual for safety
instructions, tools, specification and other details.

Measure Engine Speed
1.) Measure engine low and high idle

speed.
Read the Safety Instructions from the
Shop Manual.
Make sure all temperatures are within
working range.
Select code No. 01001 ENG SPEED from
the real time monitoring function of the
service mode and measure the engine
speeds.
Low idle: 650 – 750 RPM

High idle : 2100 – 2200 RPM

Measure T/C Stall Speed
2.) Measure torque converter stall speed.
Shop Manual.
Standard Value: working range.
Economy Mode: 1710 – 1910 RPM Select 2 items. Code No. 01001 ENG
SPEED and 40100 TC OIL TEMP from
Power Mode : 1740 - 1940 RPM the real time monitoring function of the
service mode.
Select manual shift mode 4th. gear and
release the parking brake.
Press the brake pedal and select F
(forward) or R (reverse position.
Accelerate the engine.
NOTE: Do not exceed a torque
converter oil temperature of more than
120° Celsius.

Measure Hydraulic Stall Speed
3.) Measure hydraulic stall speed.
Shop Manual.
Standard Value: working range.
Economy Mode: 1900 - 2100 RPM Select 2 items. Code No. 01001 ENG
SPEED and 04401 HYD TEMP from the
Power Mode : 2000 - 2200 RPM real time monitoring function of the
service mode.
Run the engine at high idle.
Relief the lift arm or bucket cylinder.
Measure hydraulic stall speed in E Mode
and P Mode.

Measure Full Stall Speed
4.) Measure full stall speed.
Shop Manual.
working range.
Select a display from the real time
monitoring function of the service mode.
Combine steps 2.) and 3.) explained on
the previous pages.
Standard Value:
Economy Mode: 1665 - 1865 RPM
Power Mode : 1700 - 1900 RPM

Measure Fuel Pressure
5.) Measure fuel pressure.

Shop Manual.
working range.
Remove plug (1) from the fuel filter
bracket and install a test nipple.
Run the engine at high idle in P Mode and
measure the fuel pressure.
Standard Value:

Adjust Valve Clearance
6.) Adjust valve clearance

Shop Manual.
Remove all valve covers (4), covers (1)
and (2) and bracket (3).
Rotate the crankshaft in normal direction
to align single cut (b) of the supply pump
drive gear with the center of the
inspection hole.
The left figure below indicates the TDC
position of the 1st. cylinder.
Adjust valves marked with (●) when 1st.
cylinder is at TDC.

Adjust Valve Clearance
Loosen lock nut (8) of adjustment screw

(7) and adjust the clearance by inserting a
clearance gauge (C) between crosshead
(6) and rocker arm (5) until the clearance
gauge becomes slightly movable.
Rotate the crankshaft in normal direction
to align double cut (b) of the supply pump
drive gear with the center of the
inspection hole.
The left figure below indicates the TDC
position of the 6th. cylinder.
Adjust valves marked with (○) when 6th.
cylinder is at TDC.
Valve clearance:
Intake valve 0,35 mm
Exhaust valve 0,57 mm

WA500-6
Testing & Adjusting
Transmission

Measure Transmission Pressures
1.) Measure transmission torque T/C oil inlet pressure
converter inlet pressure.
Standard: 8,55 ± 1 kg/ cm²
Make sure the transmission oil
temperature is within working range.
Install a hydraulic tester to the check
nipple.
Keep the directional lever in N and
measure the torque converter inlet
pressure in high idle.
2.) Measure transmission main

relief pressure.
nipple.
Keep the directional lever in N and Transmission main relief pressure
measure the transmission main relief
Standard at low idle: 34 ± 1,5 kg/ cm²
pressure in low and high idle. Standard at high idle 37 ± 1,5 kg/ cm²

Measure T/C Outlet Pressure
3.) Measure transmission torque
converter outlet pressure.
nipple.
Keep the directional lever in N and
measure the torque converter outlet
pressure in high idle.
T/C oil outlet pressure

Standard: 5,0 ± 1 kg/ cm²

Measure Transmission Lubrication Pressure
5.) Measure transmission lubrication pressure.
Make sure the transmission oil temperature is within working range.
Install a hydraulic tester to the check nipple.
Keep the directional lever in N and measure the transmission lubrication pressure in high idle.
Transmission lubrication pressure

Standard : Max. 2,7 kg/ cm²

Measure Transmission Pressures
6.) Measure ECMV clutch pressures.
Install a hydraulic a check nipple to
each individual ECMV valve and
connect a tester to the check nipple.
Select manual shift mode and shift to
each individual gear and travel
direction.
Release the parking brake and press
the right brake pedal.
Travel with the machine to check the
Lock-up ECMV pressure.

Reset of Transmission Initial Learning
Read the Safety Instructions from the Shop
Manual.
Display TUNING of the Service Mode.
Hold down (◊) for minimum 5 seconds to
display 01:TM TRIGGER.
Press (◊) to switch to the initial learning
screen. If TUNED is displayed, the initial
learning is completed.
Press (◊) to switch to the initial learning
reset screen. Move the cursor to YES and
confirm with (■).
Now the data in the T/M controller memory
is reset and ININTIAL STATUS is displayed.

Preparation for Transmission Initial Learning
Manual.
Before starting the transmission initial
learning carry out “Adjustment of T/M ECMV
current” and “Reset of initial learning”.
Select monitor code 93600 “T/M OIL
TEMP” and 94100 “TRIG FR1234” from the
real time monitor in Service Mode.
Make sure “000000” is displayed at monitor
code 94100 before initial learning is started.
Set the engine to low idle, select Manual
0: Learning not yet done Shift Mode and shift to 4th. gear with the
lock-up selector switch in the OFF position.
1: Learning completed
Warm up the transmission oil to 70 - 80°C.

Transmission Initial Learning
Apply the right brake pedal and release the
parking brake with the engine at low idle.
Operate the transmission controls according
to the table below.
Hold each gear for more than the specified
time.
0: Learning not yet done If the initial learning is completed “111111”
1: Learning completed is displayed at monitor code 94100.

Preparation for ECMV Tuning
Manual.
Select monitor code 93600 “T/M OIL
TEMP” from the real time monitor in Service
Mode.
Set the engine to low idle, select Manual
Shift Mode and shift to 4th. gear with the
lock-up selector switch in the OFF position.
Operate the transmission controls according
to the table below for T/M lubrication.
Warm up the transmission oil to 70 - 80°C
and make sure to maintain the oil
temperature .

ECMV Tuning
Run the engine at low idle and display the
T/M oil temperature with the accelerator
pedal in the OFF position, transmission
controls in neutral and the parking brake in
the ON position.
Selecting “ECMV TUNING AUTO”
automatically starts the ECMV current
adjustment by displaying the IP address for
each clutch.

ECMV Tuning
If ECMV TUNING is completed, “4-4 OK” is
displayed. Turn the ignition key switch to the
OFF position to save the new data in the
controller memory within the next 3
seconds.
Keep the ignition key switch in the OFF
position for at least 10 seconds.
If during ECMV TUNING an abnormality
happens, the related ECMV valve and
correction “3-1” as well as the error code
“NG1” is displayed.
In this case ECMC TUNING is cancelled.
NG1: Out of compensation range. Check and adjust the T/M oil temperature and repeat
ECMV TUNING.
NG2: No fill switch signal. Check for error codes (15S_LH) and (DXH_KA). Repair the error
codes and repeat ECMV TUNING.
NG3: Fill switch signal does not match with actual condition. Check for error codes (15S_L1).
Repair the error codes and repeat ECMV TUNING.

Transmission Shift Point Adjustment
Manual.
Hold down (◊) for minimum 5 seconds to
display 04:SHIFT rpm.
This function alters the up-shift and down-
shift speed in shift mode L, independent
from the engine mode.
With this function the transmission output
shaft speed is altered from –50 to +50 rpm,
which is approx -0,7 to +0,7 km/h.
Gear shift patterns can be changed
according the table shown on the right.

Transmission Shift Point Adjustment
The example explains the procedure to
change the dear shift pattern for F2T/C ->
F3T/C.
Select 04:SHIFT rpm and press (◊), then
select F2T/C -> F3T/C and confirm with (◊).
The initial shift speed correction value is 0
rpm.
Use (<) (>) switch to change the value, in
this example +50 rpm.
Press (◊) to confirm the shift-up correction
value
Press (■) to end the set-up procedure.

WA500-6
Testing & Adjusting
Steering System

Measure EPC Basic Pressure
The EPC basic pressure

check nipple is mounted
on the steering pump.
Standard: 38 – 40 kg/ cm²

Adjust EPC Basic Pressure Relief Valve
EPC basic
pressure
relief valve
Accumulator
charge valve
Measure Steering Pressure
R.H. steering Read the Safety Instructions from the Shop
cylinder bottom side Manual.
Make sure the hydraulic oil temperature is
within working range.
Release the internal pressure from the
hydraulic oil tank and operate the steering a
few times.
Apply the safety bar between front and rear
frame.
Install a hydraulic tester to the check nipple
and install a gauge (400 kg/ cm²).
Run the engine at high idle and apply the
steering lever / wheel.
R.H. steering
cylinder head side

Adjust Steering Pump Relief Pressure
Shop Manual.
Make sure to stop the engine prior
adjusting.
For adjustment release lock nut (11)
and turn adjustment screw (10).
Per turn the pressure increases for
183 kg/ cm².
Steering pressure relief valve

Standard: 250 - 260 kg/ cm²

Steering Pump Control Pressure Generation
P Steering pump oil

T1 To hydraulic oil tank
T2 To hydraulic oil tank
Pr To steering pump LS valve
Pa From rotary valve
Pb From rotary valve

Measure Steering Pump Control Pressure
Shop Manual.
Install a T-adapter and a check nipple
to the joint at port (Pr) and install a
gauge (25 kg/ cm²).
Run the engine with low idle and
measure the steering pump control
pressure with the steering in neutral
(12 - 14 kg/ cm²).
Run the engine at low idle and
measure the steering pump control
pressure while operating the steering
lever / wheel slowly at a continuous
speed. The pressure will drop.

WA500-6
Testing & Adjusting
Work Equipment Hydraulic System

Measure Work Equipment Pressure
To bucket cylinder bottom To bucket cylinder head
Read the Safety Instructions from the Shop Manual.

Release residential pressure from the system with the bucket on level ground.
Install a T-adapter to the check nipple on the bottom side of the bucket cylinder and install
a gauge (400 kg/ cm²).
Raise the boom off the ground and tilt back the bucket.
Run the engine with high idle and measure the work equipment pump control pressure at
bucket tilt back relief.

Adjust Work Equipment Pump Pressure
Main relief valve Front & Rear pump

325 - 345 kg/ cm²

Manual.
Release lock nut (9) and turn adjustment
screw (10) to adjust the pressure,
The pressure increases for 128 kg/ cm² per
turn.

Measure Unload and Pump Pressure
Read the Safety Instructions

from the Shop Manual.
Port PB Release residential pressure
from the system and install
check nipples to the listed
ports:
Install a T-Adapter to the hose
connected to port (PB).
Install a 60 kg/ cm² gauge to
measure Unload pressure in
Neutral.
Install a 600 kg/ cm² gauge to
measure pump pressure when
measuring LS Differential
pressure.

Unload Valve Location
Measure Unload Pressure.
Manual.
Install a hydraulic tester to following check Unload valve for rear
nipples: pump (20 kg/ cm²)
Measure the Unload Pressure at high idle
with all work equipment levers in neutral.
NOTE: The Unload Vales can not be

adjusted.
Unload valve for front

pump (20 kg/ cm²)

Measure LS Differential Pressure
Measure LS differential pressure.
Manual.
Install a differential gauge to following
check nipples:
PB Pump pressure input port
PLSC LS pressure pick-up port
Measure the LS differential pressure under

following condition:
- Raise the boom approx. 100 mm off the
ground.
- Tilt the empty bucket fully back
- Raise the boom at high idle with the
boom control lever at half stroke.
NOTE: Prevent the relief condition of the
boom cylinders.

Adjust Front & Rear Pump LS Differential Pressures
Loosen the lock nut (13) and
turn adjustment screw (14)
to adjust the LS differential
pressure on LS valve (2).
The LS differential pressure
changes for 13 kg/ cm² per
turn.
NOTE: At present there is no standard value explained in the

Shop Manual. As a reference chapter 10 indicates 14 kg/ cm²
as LS differential pressure.

Measure ECSS Accumulator Charge Pressure
Pressure reducing valve for ECSS
with check port

Manual.
Open the indicated pressure release valve to
release residential pressure from the ECSS
accumulator.
Remove the plug, install a check nipple and
and a gauge (250 kg/ cm²)
Close ECSS accumulator pressure release
valve.
Measure the ECSS accumulator charge
pressure under following condition:
• Raise the boom approx. 100 mm off the
ground.
• Tilt the empty bucket fully back to relief
ECSS accumulator
condition.
pressure release valve

Adjust ECSS Accumulator Charge Pressure
Manual.
Release the lock nut and turn the adjustment
screw to adjust the pressure.
Release the ECSS accumulator pressure
prior to the removal of the check nipple.
Pressure reducing valve

for ECSS (125 kg/ cm²)

1. Adjust Boom Raise Angle for EPC Control
Manual.
Hold down (◊) for minimum 5 seconds and
select 05:RAISE ANGLE.
Raise the boom the the highest possible
position.
Press (◊) to confirm the boom position.
When the buzzer sounds twice the setting is
completed.
When there is a one second beep from the
buzzer the set voltage does not correspond
with the machine specification.

2. Adjust Boom Raise Angle for PLM (If installed)
Manual.
select 18:RAISE ANGLE.
Raise the boom the the highest possible
position.
completed.

3. Adjust Boom Lower Angle for PLM (If installed)
Manual.
select 19:LOWER ANGLE.
Lower the boom the the lowest possible
position.
completed.

4. Adjust Boom Raise EPC
Manual.
The function is used to correct the offset of
the EPC lever.
select 06:RAISE EPC.
Raise the boom from level ground with the
bucket at horizontal position at high idle and
full EPC lever stroke.
Move the EPC lever back to neutral position
and make sure the boom will stop halfway
while the EPC lever is still applied.
Press (◊) to correct the offset of the EPC
lever.
completed.

5. Adjust Boom Lower EPC
Manual.
the EPC lever.
select 07:LOWER EPC.
Lower the boom from the highest with the
bucket at horizontal position at high idle and
full EPC lever stroke.
and make sure the boom will stop halfway
while the EPC lever is still applied.
lever.
completed.

6. Adjust Bucket Tilt Back EPC
Manual.
the EPC lever.
select 08:TILT EPC.
Raise the boom halfway and dump the
bucket fully, then tilt back the bucket at high
idle and full EPC lever stroke.
and make sure the bucket will stop at
horizontal position while the EPC lever is
still applied.
lever.
completed.

7. Adjust Bucket Dump EPC
Manual.
the EPC lever.
select 09:DUMP EPC.
Raise the boom halfway and tilt back the
bucket fully, then dump the bucket at high
idle and full EPC lever stroke.
and make sure the bucket will stop at
horizontal position while the EPC lever is
still applied.
lever.
completed.

8. Boom EPC Lever Response Adjustment
Manual.
The function is used to modify the response
of the boom EPC lever.
select 14:BOOM TABLE.
Select a new response table with the (<) /
(>) switch.
Press (■) to confirm the selection

8. Boom EPC Lever Table

8. Boom EPC Lever Curves

9. Bucket EPC Lever Response Adjustment
Manual.
The function is used to modify the response
of the bucket EPC lever.
select 15:BUCKET TBL.
(>) switch.
Press (■) to confirm the selection

9. Bucket EPC Lever Curves

10. Boom Lower Stop Modulation Adjustment
Manual.
The function is used to modify the boom
lower speed reduction rate before the boom
stops.
select 16:LOWER STOP.
(>) switch.
Press (■) to confirm the selection.
The stop modulation function acts in both,
raise and lower directions.

10. Boom Lower Stop Modulation Table
On a new machine the modulation is set to

100% as standard.


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Testing & Adjusting WA500-6

Testing & Adjusting WA500-6 Page 1 (04/2006)

Testing & Adjusting WA500-6 Page 2 (04/2006)

Testing & Adjusting WA500-6 Page 3 (04/2006)

1.) Measure engine low and high idle

Low idle: 650 – 750 RPM

Testing & Adjusting WA500-6 Page 4 (04/2006)

Testing & Adjusting WA500-6 Page 5 (04/2006)

Testing & Adjusting WA500-6 Page 6 (04/2006)

Testing & Adjusting WA500-6 Page 7 (04/2006)

5.) Measure fuel pressure.

Testing & Adjusting WA500-6 Page 8 (04/2006)

6.) Adjust valve clearance

Testing & Adjusting WA500-6 Page 9 (04/2006)

Loosen lock nut (8) of adjustment screw

Testing & Adjusting WA500-6 Page 10 (04/2006)

Testing & Adjusting WA500-6 Page 11 (04/2006)

2.) Measure transmission main

Testing & Adjusting WA500-6 Page 12 (04/2006)

T/C oil outlet pressure

Testing & Adjusting WA500-6 Page 13 (04/2006)

Transmission lubrication pressure

Testing & Adjusting WA500-6 Page 14 (04/2006)

Testing & Adjusting WA500-6 Page 15 (04/2006)

Testing & Adjusting WA500-6 Page 16 (04/2006)

Testing & Adjusting WA500-6 Page 17 (04/2006)

Testing & Adjusting WA500-6 Page 18 (04/2006)

Testing & Adjusting WA500-6 Page 19 (04/2006)

Testing & Adjusting WA500-6 Page 20 (04/2006)

Testing & Adjusting WA500-6 Page 21 (04/2006)

Testing & Adjusting WA500-6 Page 22 (04/2006)

Testing & Adjusting WA500-6 Page 23 (04/2006)

Testing & Adjusting WA500-6 Page 24 (04/2006)

The EPC basic pressure

Testing & Adjusting WA500-6 Page 25 (04/2006)

Testing & Adjusting WA500-6 Page 27 (04/2006)

Steering pressure relief valve

Testing & Adjusting WA500-6 Page 28 (04/2006)

P Steering pump oil

Testing & Adjusting WA500-6 Page 29 (04/2006)

Testing & Adjusting WA500-6 Page 30 (04/2006)

Testing & Adjusting WA500-6 Page 31 (04/2006)

To bucket cylinder bottom To bucket cylinder head

Read the Safety Instructions from the Shop Manual.

Testing & Adjusting WA500-6 Page 32 (04/2006)

Main relief valve Front & Rear pump

Read the Safety Instructions from the Shop

Testing & Adjusting WA500-6 Page 33 (04/2006)

Read the Safety Instructions

Testing & Adjusting WA500-6 Page 34 (04/2006)

NOTE: The Unload Vales can not be

Unload valve for front

Testing & Adjusting WA500-6 Page 35 (04/2006)

Measure the LS differential pressure under

Testing & Adjusting WA500-6 Page 36 (04/2006)

NOTE: At present there is no standard value explained in the

Testing & Adjusting WA500-6 Page 37 (04/2006)

Read the Safety Instructions from the Shop

Testing & Adjusting WA500-6 Page 38 (04/2006)

Pressure reducing valve

Testing & Adjusting WA500-6 Page 39 (04/2006)

Testing & Adjusting WA500-6 Page 40 (04/2006)

Testing & Adjusting WA500-6 Page 41 (04/2006)