SEBM04210108
SHOP MANUAL KOMATSU
WA450-1 MACHINE MODEL
SERIAL No.
WA450-1
10001
•
and up
ble in s and optional equipment that are not availa This shop manual may contain attachment for those items you may require. your area. Please consult your local Komatsu distributor Materials and specifications are subject to change without notice.
WA450-1 mount the S6D125-1 engine. Engine Shop Manual. For details of the engine, see the 6D125 Series
Printed in Japan 07-90(01)03321
00-1
CONTENTS 00 GENERAL
No. of page
01-1
10 ENGINE 11
STRUCTURE AND FUNCTION
11-1
12
TESTING AND ADJUSTING
12-1
13
DISASSEMBLY AND ASSEMBLY
13-1
14
MAINTENANCE STANDARD
14-1
20 POWER TRAIN 21
STRUCTURE AND FUNCTION
22 23
TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY
24
MAINTENANCE STANDARD
21-1
22-1
23-1 24-1
40 STEERING SYSTEM 41
STRUCTURE AND FUNCTION
41-1
42
42-1
43
TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY
44
MAINTENANCE STANDARD
44-1
43-1
50 BRAKE AND AIR SYSTEM 51
STRUCTURE AND FUNCTION
52 53
TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY
53-1
54
MAINTENANCE STANDARD
54-1
51-1 52-1
60 WORK EQUIPMENT SYSTEM 62-1
63
STRUCTURE AND FUNCTION TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY
64
MAINTENANCE STANDARD
64-1
61
62
61-1
63-1
80 ELECTRIC AND ELECTRONIC SYSTEM 81
STRUCTURE AND FUNCTION
81-1
82
TESTING AND ADJUSTING.
82-1
83
DISASSEMBLY AND ASSEMBLY
83-1
90 ОТHERS
00-2 ②
91
STRUCTURE AND FUNCTION
91-1
93
DISASSEMBLY AND ASSEMBLY
93-1
97
GEAR PUMP
97-1
WA450-1
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50-1 WA450
6
⑧
LIST OF REVISED PAGES
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WA450-1
e
91-5
00-2-7
IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this
manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols
are used to mark safety pre-
and
cautions 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.
ASAFETY 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
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
6. Decide
GENERAL PRECAUTIONS
precautions
given
on
the
place in the repair
a
dirt or oil on the floor.
sure that there is no
Smoke only in the areas provided smoking. Never smoke while working.
for
decals which are fixed to the machine. 2. When
carrying
out
wear safety shoes
any
operation, always
loose work clothes, or clothes with buttons
missing. •
Always wear safety glasses when hitting parts with a hammer.
safety glasses when grinding parts with a grinder, etc. Always
wear
3. If welding repairs are needed, always have a
trained, experienced welder
carry out
the
carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. When
work.
WORK
making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
7. Before
adding oil
or
machine from moving.
8. Before
starting work, lower blade, ripper,
bucket or any other work equipment to the ground. If this is
not
workers, always agree on the орbefore starting. Always
erating procedure
inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs
on
the
controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
possible, insert the
safety 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. 9. When disassembling
4. When carrying out any operation with two or more
PREPARATIONS FOR
and helmet. Do not wear
or
assembling, sup-
machine with blocks, jacks stands before starting work. port the
or
10. 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
machine. Never jump on or off the machine. If it is
impossible
to
use
the
handrails,
ladders or steps, use a stand to provide safe
footing.
00-3
19. Be sure to assemble all parts again in their
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or
hydraulic
original places. Replace any damaged parts with new parts. When installing
measuring plugs,
pressure
sure that
loosen them slowly to prevent the oil from
spurting out.
the pressure completely from the
circuit.
12. The water and oil in the circuits
are
hot
when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before car-
rying
out
any
work
on
the oil
or
water
circuits.
battery. Always remove the lead from
the negative (-) terminal first. 14. When
raising
hoist or crane.
heavy components,
use
a
damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct
are free from
a
hoist or
crane
and operate
slowly to prevent the component from hit-
ting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under internal pressure
or
under pressure froma
spring, always leave two bolts in position on opposite sides. Slowly release the pressure,
then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or
damage the wiring. Damaged
wiring may cause electrical fires.
removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to
17.When
the floor, wipe it up immediately. Fuel or oil on
the floor can
even start
cause
you to slip,
or can
fires.
18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum
parts.
00-4
be
20. When installing high pressure hoses, make sure
that
of gasoline when washing electrical
they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed.
21. When assembling or installing parts, always
the specified tightening torques. When
installing protective parts such as guards, or parts which vibrate violently
or
rotate at
high speed, be particularly careful to check that they are installed correctly. 22. When
Check that the wire rope, chains and hooks
places. Use
wires,
chine is being operated.
use
13. Before starting work, remove the leads from the
and
contact with other parts when the ma-
Before disconnecting or removing components of the oil, water or air circuits, first remove
hoses
they will not be damaged by
aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem-
bled before taking any measurements.
24. 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.
-FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand 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
of
understanding, the manual is divided
into
chapters for each
main
group
of
components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give understanding of the structure, but also serves as reference material for troubleshooting.
an
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations. MAINTENANCE
STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU
distributor for the
latest information.
00-5
HOW TO READ THE SHOP
MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK (① 2 3....)
VOLUMES 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
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series Electrical volume
Each issued as one
:
Attachments volume :
to cover all ☐ volume models
These various volumes are designed to avoid du-
plicating the same information. Therefore to deal with all repairs for any model, it is necessary that
REVISIONS Revised
pages
are
shown
at
the
LIST OF
REVISED PAGES on the between the title page and SAFETY page.
chassis, engine, electrical and attachment volumes are ready.
DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to
KOMATSU distributers. Get the most up-
to-date information before you start any work.
SYMBOLS So that the shop manual can be of ample practical use,
important places for safety and quality
are
marked with the following symbols.
FILING METHOD 1. See the page number on the bottom of the page.
Symbol
Item
File the pages in co
File the pages in correct order.
Special safety precautions are
2. Following examples show how to read the page
necessary when performing the
work.
number.
Safety
Example 1 (Chassis volume):
the wark hocauseitis undar the work because it is under
Unit number (2. Power train)
interpal pressure. pressure internal
Item number (1. Structure and
Eunctid
Special technical precautions or
Function)
.Consecutive page number for each item.
Caution
Weight of parts or systems.
410
Caution
Unit number (1. Engine)
Consecutive page No. (Page 10
kg
3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page nhor Fila number. File as in the example.
Example:
Weight
kgm
Tightening torque
A
Coat
Oil, water
21-4
12-203
21-4-1 21-4-2
-12-203-1
Added pages12-203-2
12-204
when Caution necessary necessary when
selecting hoisting wire, or when working posture is important, etc.
of Group 4)
00-6
preserving standards are
work.
Item number (2. Testing and Adjusting) Group No. (4. Fuel system)
21-5
other precautions for
necessary when performing the
Example 2 (Engine volume): 12
Extra special saley safety precautions LAla special recau are necessary when pertorming
21-3
TT
Remarks
Places that require special
attention for the tightening
torque during assembly.
Places to be coated with adhesives and lubricants etc.
Places where oil, water or fuel
must be added, and the
capacity. Drain
Places where oil or water must be drained, and quantity to be drained.
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Heavy parts (25 kg or more) must be lifted etc. In the Disassembly hoist et a noist with witr a and Asassemory and
sembly section, every part weighing 25 kg or
more is
1. If
a
indicated clearly with the symbolkg
kg
Slinging near the edge of the hook may cause the rope to to slip off the hook during hoisting, he tope sud on and a serious accident
can
result. Hooks have
maximum strength at the middle portion.
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.
100%
79%
88%
71%
41% FS0064
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetricaliy wound on to the load.
Slinging with one rope may cause turning of the load during hoisting, untwisting of
2. Wire ropes
1) Use adequate ropes depending on the weight
the rope,
of parts to be hoisted, referring to the table below:
slipping of the rope from its
4) Do not sling a heavy load with ropes forming a
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
wide hanging angle from the hook. When hoisting a load with two or more ropes,
the force subjected to each rope will increase
Rope diameter (mm)
Allowable load (tons)
10
1.0
11.2
1.4
12.5
1.6
14
2.2
16
2.8
18
3.6
20
4.4
22.4
5.6
30
10.0
40
18.0
50
28.0
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
large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.
as
kg 2000
40.0
1900
1700
2000 92
strength of the rope used.
2) Sling wire ropes from the middle portion of the
1400
1000
Load capacit
The allowable load value is estimated to be one-sixth or one-seventh of the breaking
hook.
or
original winding position on the load, which can result in a dangerous accident.
30°
60°
90°
Lifting angle:
120°
150°
a
FS0065
00-7
STANDARD TIGHTENING TORQUE
2kgm
STANDARD TIGHTENING TORQUE
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of
"Disassembly and Assembly".
of bolt
(mm)
Width across flat
(mm)
어
Thread diameter
T
H
kgm
Nm
6
10
1.35 ±0.15
13.2±1.4
8
13
3.2±0.3
31.4±2.9
10
17
6.7±0.7
65.7±6.8
12
19
11.5±1.0
112±9.8
14
22
18.0±2.0
177±19
16
24
28.5±3
279±29
18
27
39±4
383±39
20
30
56±6
549±58
22
32
76±8
745±78
24
36
94.5±10
927±98
27
41
135±15
1320±140
30
46
175±20
1720±190
33
50
225±25
2210240
36
55
280±30
2750±290
39
60
335±35
3280±340
This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. *
Nm (newton meter):
1Nm= 0.1 kgm
2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Thread diameter of bolt
(mm) 10
00-8
Tightening torque
Width
across flats
(mm)
kgm
Nm
14
6.7±0.7
65.7±6.8
12
17
11.5±1
112±9.8
16
22
28.5±3
279±29
STANDARD TIGHTENING TORQUE
kgm
Sealing surface
3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared.
R
00000000000000 FS0068
Tightening torque
Thread diameter of nut part (mm)
Width across flats
(mm)
kgm
Nm
14
19
2.5±0.5
24.5±4.9
18
24
52
49±19.6
22
27
8+2
78.5±19.6
24
32
14±3
137.3±29.4
30
36
18±3
176.5±29.4
33
41
20+5
196.1±49
36
46
25±5
245.2+49
42
55
30±5
294.2+49
of nut part
COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature
Komatsu code
Applications
LT-1A
Used to apply rubber pads, rubber gaskets, and cork plugs.
LT-1B
Used to apply resin, rubber, metallic and tallic parts when a fast, strong seal is needed.
LT-2*
Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-3
Provides an airtight, electrically insulating seal. Used for aluminum surfaces.
LG-1
Used with gaskets and packings to increase sealing effect.
LG-3
Heat-resistant gasket for precombustion chambers and exhaust piping.
LG-4
Used by itself on mounting surfaces on the final drive and transmission cases. (Thickness after tightening: 0.07 0.08 mm)
Adhesives
Liquid gasket
-
LG-5
Antifriction Antiinietion compound compound
(Lubricant including
molybdenum disulfide) Grease
esparG
(Lithium grease)
Vaseline
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
fittings in hydraulic circuits of less than 50 mm in diameter.
LM-P
Applied to bearings and taper shafts to facilitate press-fitting and to edded
G2-LI
Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and facilitation of assembling work.
prevent sticking, burning or rusting.
Used for protecting battery electrode terminals from corrosion.
*LT-2 is also called LOCTITE in the shop manuals.
00-9