CEBM002801
WA600-3L WHEEL LOADER SERIAL NUMBERS
WA600-3L - A52001
and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
SEPTEMBER 1999
Copyright 1999 Komatsu America International Company
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . 20-1 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 FOLDOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
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WA600-3L
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MEMORANDA
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WA600-3L
PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SERVICE MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIGN LANGUAGES. THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S). DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPB005000
PARTS BOOK - MICROFICHE: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPM005000
OPERATION AND MAINTENANCE MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEAM003001 3666120
SHOP MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine: Shop Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting & Repair Manual - Base Engine . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting & Repair Manual - Quantum™ System . . . . . . . . . . . . . . . . . . Troubleshooting & Repair Manual - QSK Fuel System . . . . . . . . . . . . . . . . . . . .
CEBM002801
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WLT70-1
3666133 3666098 3666113 3666232
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESSING SYSTEM (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
PUBINFOK.WPT
121297
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO
•
DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
COMPANY NAME
SHIP TO
PURCHASE ORDER NO.
• ATTN.
ORDER DATE
STREET ADDRESS
TYPE or PRINT ONLY
•
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. PARTS BOOK QTY.
KDC91E 072199
PUBLICATION FORM NO.
P-Paper M-Microfiche
PUBLICATION DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
FOREWORD
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 HOW TO READ THE SHOP MANUAL . . . . . . . . . . . . . . . . . . . . . . . . 00-5 HOISTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6 COATING MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7 STANDARD TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . 00-9 ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12 CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13
WA600-3L
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FOREWORD
SAFETY
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions 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. GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully before operating the machine.
7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not 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.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. •
Always wear safety glasses when hitting parts with a hammer.
•
Always wear safety glasses when grinding parts with a grinder, etc.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 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.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
PRECAUTIONS DURING WORK
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always 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.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
5. Keep all tools in good condition and learn the correct way to use them.
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 carrying out any work on the oil or water circuits.
6. Decide a place in the repair 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 sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
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13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative ( ) terminal first. NE G
WA600-3L
FOREWORD 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under pressure or under pressure from a 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. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
WA600-3L
SAFETY •
When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be careful to check that they are installed correctly. 22. When 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 assembled 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.
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FOREWORD
GENERAL
GENERAL 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 the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING, ADJUSTING AND TROUBLESHOOTING 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 distributor for the latest information.
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WA600-3L
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES
When a manual is revised, an edition mark (• • • ....) is recorded on the bottom outside corner of the page that is revised or new.
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
REVISIONS
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
Revised pages are recorded in the LIST OF ORIGINAL, NEW AND REVISED PAGES following the title 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
DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to your distributor. Get the most up-to-date information before you start any work.
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Item
Remarks
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
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.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example 1 (Chassis volume): 10 - 3 Section number (10. Structure and Function) Consecutive page number for each item Example 2 (Engine volume): Refer to the pertinent engine manual. 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example (Chassis volume): 10-4 10-4-1 10-4-2 • 10-5
WA600-3L
Added pages
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FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING WARNING: 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 this symbol
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If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interface with the part to be removed.
WIRE ROPES 1) Use adequate wire ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes Standard Z or S twist wire ropes without galvanizing
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Wire rope diameter (mm)
Allowable load (tons)
10 11.2 12.5 14 16 18 20 22.4 30 40 50 60
1 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10 18 28 40
3) Do not sling a heavy load with one wire rope alone, but sling with two or more wire ropes symmetrically wound on to the load. WARNING: Slinging with one wire rope may cause turning of the load during hoisting, untwisting of the wire rope, or slipping of the wire rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with wire ropes forming a wide hanging angle from the hook. When hoisting a load with two or more wire ropes, the force subjected to each wire rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two wire ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two wire ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two wire ropes make a 120• hanging angle. On the other hand, two wire ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150• .
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the wire rope used.
2) Sling wire wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the wire rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
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WA600-3L
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