Komatsu WA500-6, Shop Manual

Page 1: ...ca Corp 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...

Page 2: ...RAL 01 1 10 STRUCTURE FUNCTION AND MAINTENANCE STANDARD 10 1 20 STANDARD VALUE TABLES 20 1 30 TESTING AND ADJUSTING 30 1 40 TROUBLESHOOTING 40 1 50 DISASSEMBLY AND ASSEMBLY 50 1 60 AIR CONDITIONER 60...

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Page 20: ...FOREWORD 00 2 18 d WA500 6 Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev...

Page 21: ...s 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...

Page 22: ...ve the cover 6 When removing components be careful not to break or damage the electrical wiring Damaged wiring may cause electrical fires 7 When removing piping stop the fuel or oil from spilling out...

Page 23: ...es the judgment standards when inspecting disassembled parts 20 Standard Value Tables Section 20 explains the standard values for a new machine and judgment criteria for testing adjusting and troubles...

Page 24: ...dditional pages Additional pages are indicated by a hyphen and numbered after the page number File as in the example Example Revised Edition Mark 00 When a manual is revised an edition mark bcd is rec...

Page 25: ...slip and fall 5 Do not sling a heavy load with one rope alone but sling with two or more ropes symmetrically wound on to the load 6 Limit the hanging angle to 60 as a rule Do not sling a heavy load wi...

Page 26: ...Operation Maintenance Manual provided with the crane in advance and operate the crane safely Precautions for Using Overhead Hoist Crane 00 1 Before starting work inspect the wire ropes brake clutch c...

Page 27: ...ified position and raise the hook to at least 2 m 6 6 ft above the floor Do not leave the sling installed to the hook Selecting Wire Ropes 00 Use adequate ropes depending on the weight of parts to be...

Page 28: ...y compressor oil for refrigerant R134a DENSO ND OIL8 VALEO THERMAL SYSTEMS ZXL100PG equivalent to PAG46 to its O rings See example of O ring in the graphic O rings are fitted to every joint of the hos...

Page 29: ...ion of size of rotating shaft and hole and their relationship is shown in the graphic and this table Standard Clearance and Standard Value The clearance made when new parts are assembled is called the...

Page 30: ...rmissible value is estimated from various tests or experiences in most cases it must be judged after considering the operating condition and customer s requirement Clearance Limit Parts can be used un...

Page 31: ...more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely...

Page 32: ...take other appropriate action before passing electricity through it 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface betwee...

Page 33: ...connector portion If the machine is left disassembled for a long time it is particularly easy for improper contact to occur Always cover the connector 2 Connecting connectors A Check the connector vi...

Page 34: ...ector cannot be corrected easily remove the clamp and adjust the position If the connector clamp has been removed be sure to return it to its original position Check also that there are no loose clamp...

Page 35: ...risk that oil in the air may cause defective contact Remove all oil and water from the com pressed air before blowing with air ii Dry the inside of the connector with a dryer If water gets inside the...

Page 36: ...rrying out arc welding on the body disconnect all wiring harness connectors connected to the controller Fit an arc welding ground close to the welding point Troubleshooting Electric Circuits 00 1 Alwa...

Page 37: ...bags to prevent any dirt or dust from entering If the opening is left open or is blocked with a rag there is danger of dirt entering or of the surrounding area being soiled by leaking oil Do not use...

Page 38: ...flushing is carried out with flushing oil and secondary flushing is carried out with the specified hydraulic oil 7 Cleaning operations After repairing the hydraulic equipment pump control valve etc o...

Page 39: ...or 1 according to the following procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connector 1 toward you 3 Even if lock L2 is pressed connector 1 cannot be pulled toward you if...

Page 40: ...ccording to the following procedure While pressing lock C pull out connector 3 in the direction of the arrow 114 engine see graphic If the lock is on the underside use flat head screwdriver 1 since yo...

Page 41: ...ng lock D pull out connector 4 in the direction of the arrow 95 125 170 12V140 engines While pressing lock E of the connector pull out connector 5 in the direction of the arrow Connector Sensor SUMITO...

Page 42: ...procedure A Turn housing H1 in the direction of the arrow When the connector is unlocked housing H1 becomes heavy to turn B Pull out housing H1 in the direction of the arrow Housing H1 is left on the...

Page 43: ...show their installation position to prevent any mistake when installing Check the number and thickness of the shims and keep in a safe place When raising components be sure to use lifting equipment of...

Page 44: ...cting wiring connectors clean the connector to remove all oil dirt or water then connect securely When using eyebolts check that there is no deformation or deterioration screw them in fully and align...

Page 45: ...YSTEM Cylinder Head in the Disassembly and Assembly section 3 Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage the mounting bolts and nuts for loos...

Page 46: ...lows out prepare a container to receive the oil Connection 00 1 Hold the hose adapter 1 or hose 5 and insert it in the mating adapter 3 aligning them with each other Do not hold the rubber cap portion...

Page 47: ...the hexagonal portion at the male end 2 Hold in the condition in Step 1 and turn the lever 4 to the right clockwise 3 Hold in the condition in Steps 1 and 2 and pull out the whole body 2 to disconnec...

Page 48: ...at the male end 2 Hold in the condition in Step 1 and push until the cover 3 contacts surface a of the hexagonal portion at the male end 3 Hold in the condition in Step 1 and pull out the whole body...

Page 49: ...129 9040 250 g Polyethylene container Used as sealant for machined holes Holtz MH 705 790 126 9120 75 g Tube Used as heat resisting sealant for repairing engine Three bond 1735 179 129 9140 2 g Polyet...

Page 50: ...ype Used as sealant for flywheel housing intake manifold oil pan thermostat housing etc Three bond 1211 790 129 9090 100 g Tube Used as heat resisting sealant for repairing engines Molybdenum disulphi...

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