SEBM04250107
KOMATSU
WA5004 MACHINE
WA5004
MODEL
SERIAL
10001
No.
and up
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. WA500-1 mount the S6D140-1 engine; For details of the engine, see the 6D140-1
Series Engine Shop Manual.
00-l 05-91(02)03261
a
01 GENERAL
(THIS SECTION IS NOT USED IN THIS MANUAL) m
10 ENGINE
20 POWER TRAIN
40 STEERING
SYSTEM
m
50 BRAKE AND AIR SYSTEM
60 WORK EQUIPMENT
80 ELECTRICAL
90 OTHERS
SYSTEM
AND ELECTRONIC
SYSTEM
m
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WA5bO- 1
A
IMPORTANT
Proper service and repair is extremely The
service
and repair techniques
manual are both effective
important
injury to workers,
cautions
in this manual.
followed
carefully.
If any dangerous
safety, and take the necessary
by Komatsu
of operation.
of your machine.
and described
in this
Some of these operations
re-
by Komatsu for the purpose.
the symbols
The cautions
NOTICE
for the safe operation
recommended
and safe methods
quire the use of tools specially designed To prevent
SAFETY
A
iY
and
accompanying
situation
are used to mark safety pre* these symbols should always be
arises or may possibly arise, first consider
actions to deal with the situation.
A SAFETY GENERAL
6. Decide
PRECAUTIONS
a place
in the repair
keep tools and removed Mistakes Read
in operation
the
carefully
are extremely
Operation
dangerous.
and Maintenance
BEFORE operating
Manual
the tools Always
and parts in their correct
read
all
the
precautions
or repairs,
given
places.
sure that there is no dirt or oil on the floor.
the machine.
out any greasing
to keep
keep the work area clean and make
Smoke 1. Before carrying
workshop
parts. Always
on
only
smoking.
in
the
areas
provided
for
Never smoke while working.
the
decals which are fixed to the machine. 2.When
carrying
out
any operation,
always
wear safety shoes and helmet.
Do not wear
loose work clothes, missing.
with buttons
.
Always
or clothes
wear safety
Always
glasses when
hitting
trained, work.
wear
safety
glasses
when
experienced
always wear welding cap
and
welder
carrying
other
out
carry
out the
welding
work,
gloves, apron, glasses,
clothes
suited
for
welding
work. 4.When
carrying
inform
out any operation
work,
always
procedure your fellow
any step
agree
before
UNDER
workers REPAIR
controls in the operator’s 5. Keep all tools
in good
with two on the op-
starting.
of the operation.
hang
oil or making
any
repairs,
on hard, level ground, and
the wheels
8. Before
starting
or tracks
to prevent
the
before Before
to the
If this
equipment to
lock
warning
is not
possible,
insert
the
port
the
In addition,
control
levers
be sure
and
hang
signs on them. disassembling
the
machine
or assembling, with
blocks,
sup-
jacks
or
stands before starting work.
starting starting
machine.
and learn
lower
from falling. all
other
on the
work,
safety pin or use blocks to prevent the work
10. Remove
compartment.
the correct way to use them.
ripper,
Always
signs
condition
blade,
or any other work equipment
ground.
9. When
or more workers, erating
block
bucket
repairs are needed, always have a
When
adding
machine from moving.
grinding parts with a grinder, etc. 3. If welding
7. Before
FOR WORK
park the machine
parts with a hammer. l
PREPARATIONS
or
steps
machine. If
it
all mud and oil from
places
used
Always
to get
the steps or
on and off
use the handrails,
when
getting
on
or
the
ladders off
the
Never jump on or off the machine.
is impossible
to
use
the
handrails,
ladders or steps, use a stand to provide safe footing.
00-3
PRECAUTIONS 1 1. When or
DURING
removing
the oil filler
hydraulic
loosen
pressure
them
spurting
slowly
19 Be sure to assemble
WORK cap, drain
measuring
to prevent
plug
places.
Replace
any damaged
.
plugs,
of the
remove
oil,
the
or removing
water
pressure
compo-
or air circuits, completely
from
the
20 ‘. When
the
engine
when
oil
in the
circuits
is stopped,
are
hot
so be careful
that
rying
out
any
work
to cool before
on
the
oil
car-
or
water
starting
battery.
14 When
work,
remove
Always
the negative
(-1
remove
terminal
raising
Check
that
heavy
the
parts
lead
from
high
first.
rope,
are free from
damage.
use
lifting
ample
capacity.
Install
the
places.
use
a
equipment
a hoist
other
covers
ternal
pressure
or
spring,
always
sides. Slowly loosen
bolts
components,
removing
the floor, on the
any
in-
from
a on
the pressure,
the
piping,
be careful wiring.
not
Damaged
fires. stop
the fuel
or oil
out. If any fuel or oil drips on to
wipe
floor
with
the bolts to remove.
or damage
spilling
hit-
in position
release
it up immediately.
can cause
you
Fuel or oil
to slip, or can
even start fires. 18. As
a general
wash.parts. mum parts.
00-4
of
rule,
do
In particular, gasoline
when
not
use gasoline
to
use -only the miniwashing
not
which speed,
hoses,
twisted.
make
Damaged
so be extremely
check
for
that
high
care-
pressure
connecting
or installing tightening
protective
parts
two
fingers
caught
always When
violently
be particularly
or hand.
parts, torques.
parts such as guards,
vibrate
aligning
or
rotate
careful
or at
to check
correctly. holes,
never
Be careful
insert
your
not to get your
in a hole.
electrical
measuring the
24. Take
hydraulic
measuring
bled before
from
are under
pressure
may cause electrical
17 When from
under
leave two
removing
wiring
operate
which
the ma-
installed.
fingers
that
by the hoist or crane.
removing
break
correct
and
Do not work
when
has
at the
the component
15 When
opposite
which
or crane
part.
part still raised
then slowly
and hooks
equipment
to prevent any
chains
be by
pressure
that they are installed
23. When
lifting
Use
slowly
to
Also,
the leads from
components,
wires,
be damaged
parts
tubes
assembling
22. When
the wire
Always
16 When
are
installing
are correctly
installing
hoist or crane.
ting
high
use the specified
13 Before
not
other
they
ful when
21 When
circuits.
the
will
are dangerous,
circuits.
not to get burned. Wait for the oil and water
with
installing
sure and
they
new parts.
and
chine is being operated.
tubes water
hoses
in their
first
circuit. 12 The
that
again
parts with
installing
contact
disconnecting
nents
When sure
the oil from
out.
Before
all parts
original
care
taking when
tracks
of track-type removing
either
pressure,
check
is correctly
assem-
any measurements. removing
When
rates suddenly,
tool
or installing
the
machines. the
track,
so never
end of the track.
the
track
let anyone
sepa-
stand
at
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FOREWORD
This shop serviceman
manual
has been prepared
an accurate
understanding
repairs and make judgements.
as an aid to improve
of the product
the quality
and by showing
Make sure you understand
of repairs
by giving the
him the correct way to perform
the contents
of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains
the necessary
technical
information
for operations
performed
in
a service workshop. For
ease
components;
of
understanding,
these chapters
STRUCTURE
AND
This
section
adjustments
This
section
assembling MAINTENANCE
into
chapters
for
each
main
group
of
sections.
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material for troubleshooting.
ADJUSTING explains
checks
to be made
to be made at completion
Troubleshooting DISASSEMBLY
is divided
FUNCTION
an understanding AND
manual
are further divided into the following
This section explains
TESTING
the
charts correlating
AND
before
and after
performing
repairs,
as well
as
of the checks and repairs.
“Problems”
to “Causes”
are also included in this section.
ASSEMBLY
explains
the order to be followed
each component,
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD
This section gives the judgement
standards
when inspecting
disassembled
parts.
NOTICE The
specifications
contained
in this
shop
time
and without
any advance
notice.
Contact
latest
manual your
are
subject
KOMATSU
to change
at any
distributor
for the
information.
00-5
HOW
TO READ THE SHOP
MANUAL
HOW
TO READ THE SHOP
MANUAL
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.
volume:
Engine volume:
Issued for every machine model Issued for each engine series
Electrical volume Attachments volume
: :
I
Each issued as one volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION
MARK
-... )
REVISED
Chassis
EDITION
(a@@
VOLUMES
AND
UPDATING
Any changes Get the you start
amendments or other additions, will be sent to KOMATSU distributers. most up-to-date information before any work.
FILING
METHOD
REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page.
SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.
Symbol
1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volume):
1 Item
Remarks Special safety precautions are necessary when performing the work.
A Safety
Extra special safety precautions are necessary when performing the work because it is under internal pressure.
YY 9
IO-3
17_
Item number (I 0. Structure and Function) Consecutive page number for each item.
Special technical precautions other precautions for preserving standards are necessary when performing work.
Caution
*
Example 2 (Engine volume):
T
Weight
3. Additional pages: Additional pages are indicated by a hyphen (-1 and number after the page number. File as in the example. Example:
?
4 4
1 o-4
12-203
1 o-5
12-204
00-6
Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants
Oil, water
A
Drain
the
Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
12-410 Unit number (I. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4)
or
etc.
Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
HOISTING
INSTRUCTIONS
HOISTING
INSTRUCTIONS
A Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol &
1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: . Check for removal of all bolts fastening the part to the relative parts. . Check for existence of another part causing interference with the part to be removed.
2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
(mm)
Allowable
load (tons)
10
1 .o
11.2
1.4
12.5
1.6
14
2.2
16
2.8
18
3.6
20
4.4
22.4
5.6 10.0
30 40
18.0
50
28.0
60
40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
as%
79%
71%
41% FSO064
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. Slinging with one 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.
A
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120” hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150”. A
A
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes of the hook.
from
the middle
portion Lifting
angle
: a FSO065
00-7
STANDARD
TIGHTENING
TORQUE
STANDARD 1. STANDARD
TIGHTENING
TIGHTENING
TORQUE
OF BOLTS
The following charts give the standard tightening sections of “Disassembly and Assembly”.
Thread diameter of bolt (mm)
AND torques
TORQUE NUTS of bolts and nuts. Exceptions
are given in
Width across flat (mm)
kgm
Nm
6
10
1.35kO.15
8
13
3.2kO.3
31.4t2.9
10
17
6.7f0.7
65.7k6.8
12
19
11.5+1.0
112k9.8
14
22
18.0~2.0
177r19
16
24
28.5t3
279+29
18
27
39I+4
20
30
56+6
13.22
383t39 549k58
22
32
76-t8
745r+78
24
36
94.5*10
927*98
27
41
30
46
33
50
36
55
39
60
1.4
This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening to otherwise specified torque. *
Nm (newton
2. TIGHTENING
meter):
TORQUE
INm
& 0.1 kgm
OF SPLIT
FLANGE
BOLTS
Use these torques for split flange bolts.
Threa$
00-8
gtlyeter
Tightening
torque
(mm)
Width across flats (mm)
10
14
12
17
11.5&l
112k9.8
16
22
28.5+3
279229
kgm 6.71~0.7
Nm 65.7k6.8