Komatsu Wa500 1 Wheel Loader Service Repair Manual Download 10001 And Up

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

CONTENTS 10 ENGINE 11 - 12

No. of page

STRUCTURE TESTING

AND FUNCTION

.........................................

AND ADJUSTING

13

DISASSEMBLY

...........................................

AND ASSEMBLY ......................................

14

MAINTENANCE

STANDARD

20

POWER

21

STRUCTURE TESTING

23

DISASSEMBLY

24

MAINTENANCE

AND

FUNCTION

.........................................

AND ADJUSTING

...........................................

AND ASSEMBLY ......................................

STANDARD ...........................................

STEERING

SYSTEM AND FUNCTION

41

STRUCTURE

42

TESTING

43

DISASSEMBLY

44

MAINTENANCE

.........................................

AND ADJUSTING

...........................................

AND ASSEMBLY ......................................

STANDARD ...........................................

50 BRAKE AND 51

STRUCTURE

52

TESTING

53

DISASSEMBLY

54

MAINTENANCE

60 WORK

AND FUNCTION

.........................................

...........................................

AND ASSEMBLY ......................................

STANDARD ...........................................

EQUIPMENT

61

STRUCTURE TESTING

AND

FUNCTION

.........................................

63

DISASSEMBLY

...........................................

AND ASSEMBLY ......................................

64

MAINTENANCE

STANDARD

81

STRUCTURE

82

TESTING

83

DISASSEMBLY

22-1 23-l 24-1

41-1 42-l 43-1 44-l

AND

...........................................

ELECTRONIC

AND FUNCTION

51-l 52-1 53-l 54-l

SYSTEM

AND ADJUSTING

ELECTRIC

21-1

AIR SYSTEM

AND ADJUSTING

62

80

14-1

13-l

TRAIN

22

40

...........................................

11-l

12-1

61-l 62-l 64-l

63-1

SYSTEM

.........................................

AND ADJUSTING

...........................................

AND ASSEMBLY ......................................

81-1 82-l 83-1

90 OTHERS 91 93 97

OTHERS..

............................................................

DISASSEMBLY AND ASSEMBLY ......................................

GEAR PUMP ........................................................

Ok2

91-1 93-1 97-101

WA500-

1

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

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

.

STANDARD

TIGHTENING

TORQUE

Sealing surface

3.TlGHTENlNG Use these

TORQUE torques

FOR

NUTS

OF

FLARED

for nut part of flared.

T

Tightening

Thread diameter of nut part (mm)

Width across flats of nut part (mm)

14

19

2.520.5

18

24

5k-2

Nm

kgm

24.5 24.9 49k19.6

22

27

8k2

24

32

14k3

137.3k29.4

30

36

1823

176.5 k29.4

33

41

2OC5

196.1

36

46

25+5

245.2*49

42

55

3OA5

294.2249

COATING The recommended

coating

Nomenclature

materials

I

Grease (Lithium grease)

249

MATERIALS in Komatsu

Shop

Manuals

are listed

below.

Applications

LT-1A

Used to apply rubber pads, rubber gaskets, and cork plugs.

LT-IB

Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed.

LT-2’

Preventing

LT-3

Provides an airtight, electrically Used for aluminum surfaces.

LT-4

Used to coat plugs (plate shaped, bowl shaped) and holes, and mating portion of shaft.

LG-1

Used with gaskets and packings to increase sealing effect.

LG-3

Heat-resistant gasket for precombustion and exhaust piping.

LG-4

Used b itself on mounting surfaces on the%al drive and transmission cases. YThrckness after tightening: 0.07 - 0.08 mm)

LG-5

Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittinas in hvdraulic circuits of less than 50 mm in diameter.

Sealant gasket

Antifriction compound (Lubricant including molvbdenum disulfide)

prescribed

78.5 f 19.6

Komatsu code

Adhesives

Vaseline

torque

LG-6

bolts, nuts and plugs from loosening and leaking oil. insulating seal.

1 Srlrcon ‘. base type used in combination

chambers -

with LG-1 and LG-4.

LG-7

Has a shorter curing time than LG-6, and is easier to peel off.

LM-P

Applied to bearings and taper shafts to facilitate prevent sticking, burning or rusting.

G2-LI

Applied to bearings, sliding parts and oil seals for lubrication, prevention and facilitation of assembling work.

-

Used for protecting

battery electrode

press-fitting

and to

rust

terminals from corrosion.

“LT-2 is also called LOCTITE in the shop manuals

00-9

ELECTRIC WIRE

CODE

ELECTRIC In the wiring

diagrams,

various

colors

and symbols

This wire code table will help you understand Example:

5WB

indicates

CLASSIFICATION

a cable

having

a nominal

Number

Dia. Tp$nds

to indicate

the thickness

of wires.

DIAGRAMS.

number

5 and white

coating

with

black stripe.

Cross section

Cable O.D.

Current rating

(mm)

(A)

2.4

12

Applicable

circuit

(mm*)

11

0.85

CODE

BY THICKNESS

strands 0.32

0.88

Starting,

lighting, signal etc.

2

I

26

1

0.32

1

2.09

1

3.1

1

20

1

Lighting,

signal etc.

5

1

65

1

0.32

1

5.23

1

4.6

I

37

(

Charging

and signal

15

84

0.45

13.36

7.0

59

Starting

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

217

0.80

230

Starting

I

100

CLASSIFICATION

1

are employed

WIRING

Copper wire

Nominal number

Prioritv

WIRE

I\

BY COLOR

109.1

AND

CODE

Charging

Starting

Ground

Lighting

I

I tPri-

I

Circuits

Classk fication

marY

17.6

(Glow plug)

Code Red

Color

RW White&

Red

WB White & Black

I

-

I

Black&White BY Black &Yellow

Red & White RB Red & Black RY

YB

I

GR

Yellow & Black 1 Green & Red YG

I

GY

I

LR

1

Blue & Red

I

LY

Red & Yellow RG

00-l 0

Red & Green

Yellow & Blue

RL

YW

(GL)

Red & Blue

Yellow & White

(Green & Blue)

-

WEIGHT

A

TABLE

This weight table is a guide for use when transporting

or handling components.

Unit.

Machine Model

WA500- 1

Machine Model

Serial Number

10001 -

Serial Number pump

I

WA500-1 10001 -

Engine assembly

1453

Hydraulic

Radiator

assembly

285

Steering and POC pumps

Torque converter assembly

193

Switch pump

I

13

Transmission assembly

980

POC valve

I

5

I

Damper

91

Machine control valve

Upper drive shaft

18

Lift cylinder

Center drive shaft

33

Dump cylinder

Front drive shaft

44

Engine hood

Rear drive shaft

42

Front frame

Front axle assembly

2028

Rear axle assembly

1776

Front differential

288

Rear differential

assembly assembly

282

Planetary carrier assembly (1 piece)

80

Planetary hub assembly (1 piece)

102

Axle pivot (Rear axle)

(1 piece)

Lift arm (with bushing)

20

90 279 283 43

I

1996

931119

I

Tire (1 piece)

421

Battery (1 piece)

Steering valve

55

Cab assembly

47

Air conditioner

Brake (1 piece)

170

Hydraulic

156

WA500-1

I

13

2486

Fuel tank

tank

I

I

240

(1 piece)

I

I

Wheel (1 piece)

Steering cylinder

kg

328 53 305

unit

I

115

Operator’s seat

I

40

Floor plate

I

131

0°2’

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