Shop Manual
WHEELLOADER
SERIALNUMBERSWA500-3LEA70001andup
ENGINE NTA14C
ThismaterialisproprietarytoKomatsuAmericaCorp.andisnottobereproduced,used,ordisclosedexceptin accordancewithwrittenauthorizationfromKomatsuAmericaCorp.
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Duetothiscontinuousprogramofresearchanddevelopment,revisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
Copyright2013Komatsu PrintedinU.S.A. KomatsuAmericaCorp. March2013
VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOP MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALS INFOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
Theaffectedpagesareindicatedwiththe followingmarks.Pleaseupdatethemanualby deleting,replacingand/oraddingpages accordingtoinformationinthetablebelow. SymbolIndicationAction ONewpagestobeaddedAdd PagestobereplacedReplace ()PagestobedeletedDiscard Pageswithoutsymbolsarenotrevisedatthis time.
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SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.Readthe7.Beforeaddingoilormakingrepairs,parkthemachineon OPERATION&MAINTENANCEMANUALcarefullyBEFOREhard,levelground,andblockthewheelsortracksto operatingthemachine.preventthemachinefrommoving.
1.Beforecarryingoutanygreasingorrepairs,readallthe8.Beforestartingwork,lowerblade,ripper,bucketorany precautionsgivenonthedecalswhicharefixedtotheotherworkequipmenttotheground.Ifthisisnot machine.possible,insertthesafetypinoruseblockstopreventthe
workequipmentfromfalling.Inaddition,besuretolock
2.Whencarryingoutanyoperation,alwayswearsafetyallthecontrolleversandhangwarningsignsonthem. shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.9.Whendisassemblingorassembling,supportthemachine withblocks,jacksorstandsbeforestartingwork.Alwayswearsafetyglasseswhenhittingpartswitha hammer.
Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedurebefore starting.Alwaysinformyourfellowworkersbeforestarting anystepoftheoperation.Beforestartingwork,hang UNDERREPAIRsignsonthecontrolsintheoperator's compartment.
5.Keepalltoolsingoodconditionandlearnthecorrectway tousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsand removedparts.Alwayskeepthetoolsandpartsintheir correctplaces.Alwayskeeptheworkareacleanand makesurethatthereisnodirtoroilonthefloor.Smoke onlyintheareasprovidedforsmoking.Neversmoke whileworking.
PREPARATIONSFORWORK
10.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersorsteps,usea standtoprovidesafefooting.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugorhydraulic pressuremeasuringplugs,loosenthemslowlytoprevent theoilfromspurtingout.Beforedisconnectingor removingcomponentsoftheoil,wateroraircircuits,first removethepressurecompletelyfromthecircuit.
12.Thewaterandoilinthecircuitsarehotwhentheengine isstopped,sobecarefulnottogetburned.Waitforthe oilandwatertocoolbeforecarryingoutanyworkonthe oilorwatercircuits.
13.Beforestartingwork,removetheleadsfromthebattery.19.Besuretoassembleallpartsagainintheiroriginalplaces. ALWAYSremovetheleadfromthenegative(-)terminal first.
14.Whenraisingheavycomponents,useahoistorcrane. Checkthatthewirerope,chainsandhooksarefreefrom damage.Alwaysuseliftingequipmentwhichhasample capacity.Installtheliftingequipmentatthecorrectplaces. Useahoistorcraneandoperateslowlytopreventthe componentfromhittinganyotherpart.Donotworkwith anypartstillraisedbythehoistorcrane.
15.Whenremovingcoverswhichareunderinternalpressure orunderpressurefromaspring,alwaysleavetwobolts inpositiononoppositesides.Slowlyreleasethepressure, thenslowlyloosentheboltstoremove.
16.Whenremovingcomponents,becarefulnottobreakor damagethewiring,Damagedwiringmaycauseelectrical fires.
17.Whenremovingpiping,stopthefueloroilfromspilling out.Ifanyfueloroildripsontothefloor,wipeitup immediately.Fueloroilonthefloorcancauseyoutoslip, orcanevenstartfires.
18.Asageneralrule,donotusegasolinetowashparts.In particular,useonlytheminimumofgasolinewhen washingelectricalparts.
Replaceanydamagedpartwithnewparts.
Wheninstallinghosesandwires,besurethatthey willnotbedamagedbycontactwithotherparts whenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesurethatthey arenottwisted.Damagedtubesaredangerous,sobe extremelycarefulwheninstallingtubesforhighpressure circuits.Alsocheckthatconnectingpartsarecorrectly installed.
21.Whenassemblingorinstallingparts,alwaysusethe specifiedtighteningtorques.Wheninstallingprotective partssuchasguards,orpartswhichvibrateviolentlyor rotateathighspeed,beparticularlycarefultocheckthat theyareinstalledcorrectly.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.Becarefulnottogetyourfingerscaughtinahole.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetakingany measurements.
24.Takecarewhenremovingorinstallingthetracksoftracktypemachines.Whenremovingthetrack,thetrack separatessuddenly,soneverletanyonestandateither endofthetrack.
FOREWORD
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurateunderstanding oftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyouunderstandthecontents ofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.Foreaseof understanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmaingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantandlubricant specificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthestructure, butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeatcompletion ofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent,aswell asprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMESREVISEDEDITIONMARK
Shopmanualsareissuedasaguidetocarryingoutrepairs. Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverallmodels
Attachmentvolume:Eachissuedasonetocoverallmodels
Thesevariousvolumesaredesignedtoavoidduplicationof information.Thereforetodealwithallrepairsforanymodel,itis necessarythatchassis,engineelectricalandattachmentbe available.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesenttoyour distributors.Getthemostup-to-dateinformationbeforeyoustart anywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.Filethe pagesincorrectorder.
2.Followingexamplesshowhowtoreadthepagenumber: Example1(Chassisvolume): 10-3
Itemnumber(10.StructureandFunction)
Consecutivepagenumberforeach item
Example2(Enginevolume): Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.Fileasin theexample. Example: 10-4 10-4-1Addedpages 10-4-2 10-5
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.
SymbolItemRemarks
Safetynecessarywhenperformingthe
Caution
Weight
Tighteningtorque
Specialsafetyprecautionsare work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuelmustbeadded,andthecapacity.
Draindrained,andquantitytobe
Placeswhereoilorwatermustbe drained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbeliftedwitha hoistetc.IntheDISASSEMBLYANDASSEMBLY section,everypartweighing25kgormoreisindicated clearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthemachineby hoisting,thefollowingchecksshouldbemade:
1)Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2)Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
WIREROPES
1)Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes (Standard"Z"or"S"twistropeswithoutgalvanizing Ropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
Slingingwithoneropemaycauseturningofthe loadduringhoisting,untwistingoftherope,or slippingoftheropefromitsoriginalwindingpositiononthe load,whichcanresultinadangerousaccident.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelowshows thevariationofallowableload(kg)whenhoistingismade withtworopes,eachofwhichisallowedtoslingupto 1000kgvertically,atvarioushangingangles.Whentwo ropesslingaloadvertically,upto2000kgoftotalweight canbesuspended.Thisweightbecomes1000kgwhen tworopesmakea120r hand,tworopesaresubjecttoanexcessiveforceas largeas4000kgiftheyslinga2000kgloadatalifting angleof150
Theallowableloadvalueisestimatedtobe1/6or1/7of thebreakingstrengthoftheropeused.
2)Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetherope toslipoffthehookduringhoisting,andaseriousaccident canresult.Hookshavemaximumstrengthatthemiddle portion.
