KOMATSU WA500-1 WHEEL LOADER Service Repair Manual SN：10001 and up

SEBM04250107
KOMATSU
WA5004
MACHINE MODEL SERIAL No.
WA5004 10001 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.
05-91(02)03261
00-l
a

CONTENTS
10 ENGINE No. of page
11 STRUCTURE AND FUNCTION ......................................... 11-l
- 12 TESTING AND ADJUSTING ........................................... 12-1
13 DISASSEMBLY AND ASSEMBLY ...................................... 13-l
14 MAINTENANCE STANDARD ........................................... 14-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION ......................................... 21-1
22 TESTING AND ADJUSTING ........................................... 22-1
24 MAINTENANCE STANDARD ........................................... 24-1
40 STEERING SYSTEM
42 TESTING AND ADJUSTING ........................................... 42-l
43 DISASSEMBLY AND ASSEMBLY ...................................... 43-1
44 MAINTENANCE STANDARD ........................................... 44-l
50 BRAKE AND AIR SYSTEM
52 TESTING AND ADJUSTING ........................................... 52-1
60 WORK EQUIPMENT SYSTEM
80 ELECTRIC AND ELECTRONIC SYSTEM
90 OTHERS
91 OTHERS.. ............................................................ 91-1
97 GEAR PUMP ........................................................ 97-101
Ok2 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 SYSTEM
80 ELECTRICAL AND ELECTRONIC SYSTEM
m
90 OTHERS

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WA5bO- 1

A 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 re-
quire the use of tools specially designed by Komatsu for the purpose.
A
iY
To prevent injury to workers, the symbols and
*
are used to mark safety pre-
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.
A SAFETY
GENERAL PRECAUTIONS
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 precautions given on 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, or clothes with buttons
missing.
. Always wear safety glasses when hitting
parts with a hammer.
l Always wear safety glasses when
grinding parts with a grinder, etc.
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.
4.When carrying out any operation with two
or more workers, always agree on the op-
erating 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.
5. Keep all tools in good condition and learn
the correct way to use them.
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.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
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.
9. When disassembling or assembling, sup-
port 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.
00-3

PRECAUTIONS DURING WORK
1 1. 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 compo-
nents of the oil, water or air circuits, first
remove 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.
13 Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (-1 terminal first.
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 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 in-
ternal 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 mini-
mum of gasoline when washing electrical
parts.
19 Be sure to assemble all parts again in their
original places.
Replace any damaged parts with new parts.
. When installing hoses and wires, be
sure that they will not be damaged by
contact with other parts when the ma-
chine is being operated.
20 ‘. When installing high pressure hoses, make
sure that 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
use 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 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 sepa-
rates suddenly, so never let anyone stand at
either end of the track.
00-4

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
an understanding of the structure, but also serves as reference material for troubleshooting.
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
VOLUMES
Shop manuals are issued as a guide to carry-
ing out repairs. They are divided as follows:
Chassis volume: Issued for every machine
model
Engine volume: Issued for each engine series
Electrical volume :
I
Each issued as
Attachments volume :
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 neces-
sary that chassis, engine, electrical and attach-
ment 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.
FILING METHOD
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):
IO-3
17_
Item number (I 0. Structure
and Function)
Consecutive page number for
each item.
Example 2 (Engine volume):
12-410
T
Unit number (I. Engine)
Item number (2. Testing and
Adjusting)
Group No. (4. Fuel system)
Consecutive page No. (Page
10 of Group 4)
3. Additional pages: Additional pages are in-
dicated by a hyphen (-1 and number after the
page number. File as in the example.
Example:
1o-4 12-203
REVISED EDITION MARK (a@@ -... )
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
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 Item
A
Safety
YY
9
* Caution
Weight
4 Oil, water
4
A Drain
?
Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for
preserving standards are
necessary when performing the
work.
Weight of parts or systems.
Caution necessary when
selecting hoisting wire, or when
working posture is important,
etc.
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.
Places where oil or water must
be drained, and quantity to be
drained.
1o-5 12-204
00-6

HOISTING INSTRUCTIONS
A Heavy parts (25 kg or more) must be
lifted with a hoist etc. In the Disassembly
and Assembly section, every part weigh-
ing 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
30 10.0
40 18.0
50 28.0
60 40.0
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 from the middle portion
of the hook.
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.
A 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.
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
Lifting angle : a
FSO065
00-7

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”.
Thread diameter Width
of bolt across flat
(mm) (mm)
kgm Nm
6 10 1.35kO.15 13.22 1.4
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 383t39
20 30 56+6 549k58
22 32 76-t8 745r+78
24 36 94.5*10 927*98
27 41
30 46
33 50
36 55
39 60
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):
2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
INm & 0.1 kgm
Use these torques for split flange bolts.
Threa$ gtlyeter
(mm)
10
12
16
Width
across flats
(mm)
14
17
22
Tightening torque
kgm Nm
6.71~0.7 65.7k6.8
11.5&l 112k9.8
28.5+3 279229
00-8

.
Sealing surface
3.TlGHTENlNG TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter Width across flats
of nut part of nut part
(mm) (mm)
T
kgm
14 19 2.520.5
18 24 5k-2
22 27 8k2
24 32 14k3
30 36 1823
33 41 2OC5
36 46 25+5
42 55 3OA5
COATING MATERIALS
Nm
Tightening torque
24.5 24.9
49k19.6
78.5 f 19.6
137.3k29.4
176.5 k29.4
196.1 249
245.2*49
294.2249
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Nomenclature Komatsu code
LT-1A
Applications
Used to apply rubber pads, rubber gaskets, and cork plugs.
Adhesives
LT-IB
LT-2’
LT-3
Used to apply resin, rubber, metallic and
non-metallic parts when a fast, strong seal is needed.
Preventing bolts, nuts and plugs from loosening and leaking oil.
Provides an airtight, electrically insulating seal.
Used for aluminum surfaces.
LT-4 Used to coat plugs (plate shaped, bowl shaped) and holes, and
mating portion of shaft.
Sealant gasket
LG-1
LG-3
LG-4
LG-5
Used with gaskets and packings to increase sealing effect.
Heat-resistant gasket for precombustion chambers
and exhaust piping.
-
Used b itself on mounting surfaces on the%al drive and transmission
cases. Thrckness after tightening: 0.07 - 0.08 mm)Y
Used by itself to seal grease fittings, tapered screw fittings and tapered
screw fittinas in hvdraulic circuits of less than 50 mm in diameter.
I LG-6 1 ‘.Srlrcon base type used in combination with LG-1 and LG-4.
Antifriction compound
(Lubricant including
molvbdenum disulfide)
LG-7
LM-P
Has a shorter curing time than LG-6, and is easier
to peel off.
Applied to bearings and taper shafts to facilitate press-fitting and to
prevent sticking, burning or rusting.
Grease
(Lithium grease)
G2-LI Applied to bearings, sliding parts and oil seals for lubrication, rust
prevention and facilitation of assembling work.
Vaseline - Used for protecting battery electrode terminals from corrosion.
“LT-2 is also called LOCTITE in the shop manuals
00-9

ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Nominal
number
0.85
Copper wire
Cable O.D. Current rating
Number Dia. Tp$nds Cross section (mm) (A)
Applicable circuit
strands (mm*)
11 0.32 0.88 2.4 12 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 (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100
I 217 0.80 109.1 17.6
I
230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Prior-
itv
IClassk
fication
Charging
I
Ground Starting Lighting
1
Pri-
Code
I t-marY Color Red
RW
White& Red I - I Black&White Red & White
RB YB
I GR
I LRWB - BY
White & Black - Black &Yellow Red & Black Yellow & Black 1 Green & Red 1 Blue & Red
RY YG I GY I LY
Red & Yellow
Yellow & Blue
RG
Red & Green
YW (GL) -
Yellow & White (Green & Blue)
RL
Red & Blue
00-l0

WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit. kg
Machine Model WA500- 1
Serial Number 10001 -
Engine assembly 1453
Radiator assembly 285
Torque converter assembly 193
Transmission assembly 980
Damper 91
Upper drive shaft 18
Center drive shaft 33
Front drive shaft 44
Rear drive shaft 42
Front axle assembly 2028
Rear axle assembly 1776
Front differential assembly 288
Rear differential assembly 282
Planetary carrier assembly (1 piece) 80
Planetary hub assembly (1 piece) 102
Axle pivot (Rear axle) 931119
Wheel (1 piece) 240
Tire (1 piece) 421
Steering valve 55
Steering cylinder (1 piece) 47
Brake (1 piece) 170
Hydraulic tank 156
Machine Model
I
WA500-1
Serial Number 10001 -
Hydraulic pump
I
13
Steering and POC pumps
I
20
Switch pump
I
13
POC valve I 5
Machine control valve
I
90
Lift cylinder (1 piece)
I
279
Dump cylinder
I
283
Engine hood
I 43
Front frame 2486
Lift arm (with bushing)
I
1996
Fuel tank
I 328
Battery (1 piece)
Cab assembly
53
305
Air conditioner unit
I
115
Operator’s seat I 40
Floor plate
I 131
WA500-1
0°2’

TABLE OF OIL AND COOLANT QUANTITIES
RESERVOIR
Engine oil pan
Brake
Transmission case
Hydraulic system
Axle
(Front and rear)
Fuel tank
Cooling system
KIND OF
AMBIENT TEMPERATURE CAPACITY IQ)
.FLUID
_22 -240 14 32 50 68-30 -10 0 10 20 ‘2 ‘$E Specified Refill
~~~,~~~~~~~,~~
-l-‘““” I I !32 28.5
,.,,I,,,..,.....,.:_.,.,.,,,.,‘.,.(.,,,.,..,....!...
Engine oil
See NOTE (4) each 75 1 each 75
Water Add antifreeze 80 _
ASTM: American Society of Testing and Material
SAE: Society of Automative Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic mainte-
nance hours described in this manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
(2)
(3)
I
Fuel sulphur content
Change interval of oil
in engine oil pan
I
(4)
0.5 to 1.0%
~
l/2 of regular interval
Above 1.O%
I l/4 of regular interval
*
When starting the engine in an atmospheric tem-
perature of lower than O°C, be sure to use engine
oil of SAElOW, SAElOW-30 and SAE15W-40,
even though an atmospheric temperature goes up
to 10°C more or less in the day time.
Use API classification CD as engine oil and if API
classification CC, reduce the engine oil change
interval to half.
For axle oil, use only recommended oil as follows.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
If noise comes from the brake, it is no problem of
durability.
0°i2
WA500- 1

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
4. Bearing separator
FSOO 13
02P-023
5. Hook wrench
A hook wrench has a claw which hooks into the
turning sockets of round nuts. The wrench size is
defined by the outer diameter of the round nut
turned. The accompanying figure shows a hook
wrench designed for use with round nuts of two
different sizes.
FSOOl4
:’
FSOO15
Removal and Installation of the Sprocket Wheel
FSOO16
00-l 3

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
S.CLEARANCE ADJUSTMENTS
Store each set of shims or washers so that they
can be installed in their original condition at the
time of reassembly.
10. LINK RODS
1) If it is necessary to change the length of the
link rod in order to remove it, first record the
original length so that the rod can be easily
reassembled in its original condition.
2) Remove the link rod at the pins.
Rod
0 0
r-l”----” o] 0
n
11 .SHIMS AND WASHERS
1) Shims are used to center the engine and
adjust the action of the bevel gears. Handle
very carefully as they get deformed easily.
2) Record the numbers and positions to speed
adjustment after reinstallation.
3) Do not reuse any shims or washers that are
deteriorated, damaged, bent or deformed.
4) Insert thin shims between thicker ones.
12. CENTERING
Centering is very important for interfaces in the
power train - for example, between the engine
and the transmission and between the
bevel gear shaft and the final drives. Incorrect
centering only increases the stresses acting on
the turning parts, so always make sure that the
deviation is within the specified limits.
Engine
Transmission
w Correct
Yoke Pin
FSOOI 7
Transmission
Correct
FSOO18
00-14

MEASURING INSTRUCTIONS
PREPARATIONS BEFORE CHECKING BLOCK GAUGES
1. Cleaning of parts
Wash parts to be checked. Special care should be
paid to thoroughly remove dust and dirt from the
surfaces on which measurements are to be made
so that possible errors can be eliminated.
2. Minor repair of part surfaces
Remove scratches, dents and rust from parts to
be checked. If the surface are rough, the measure-
ments will be inaccurate. When smoothing any
surface, be careful not to use an oilstone or sand
paper coarser than the finished surface.
3. Preparation of measuring tools
Clean the tools and thoroughly remove dust and
dirt from the surfaces which contact parts. Check
the tools for proper function and zero-point
adjustment. Remedy any abnormality.
4. Maintenance of measuring tools
Handle all tools with sufficient care and do not
subject them to unreasonable force or shocks
which can affect their delicate construction. Peri-
odically check the tools for accuracy and, if
necessary, calibrate them. Put the tools back into
their cases and return them to their fixed storage
locations whenever not in use. It is recommended
to assign a person to be responsible for the proper
storage of measuring tools.
MEASURING TOOLS
Repeat each measurement two or three times to
eliminate possible errors. Further repetition will be
necessary, if there is a large variation in the
readings.
When measuring the inside or outside diameter of
a cylindrical object, take two readings with the
measuring device put in two directions at right
angles to each other. Repeat this at several points
along the overall length of the object.
Along eye-measurement below the unit of a scale
may be used for making a comparison between
two approximately equal measurements, the accu-
racy of such eye-measurements should not be
considered as reliable.
At the start of each measurement, select a
measuring device having an accuracy appropriate
for judging whether the measurement reaches its
allowable limit.
To bring two blocks into contact, wash each block
with benzene to remove rust-preventing oil and
wipe with a clean cotton cloth. Put one block on
the other, causing a sliding or twisting movement
between the two.
If the contact between two blocks feels rough,
apply a fine-grade oilstone to’ the blocks along
their edges. (Do not try to rub thecontact surface
of the blocks.)
Do not leave the blocks in contact for a long time.
Long-time contact will make the blocks difficult to
separate or cause black rust to appear on the con-
tact surfaces.
When separating two blocks, slide or twist them.
Do not try to pull them apart, by force or strike
them with a mallet.
When storing a block gauge, wipe off moisture,
dirt and fingerprints, coat with a rust-preventing
lubricant such as Vaseline, and put the gauge back
in its case.
VERNIER CALIPERS
At the start of measurement, close the jaws and
check that there is no clearance (due to wear) be-
tween the jaws and that the “zero” point of the
graduation is in exact alignment with the “zero”
point of the vernier scale.
Measuring an outer diameter
Correct
FSOO 19
00-l 5

l Measuring an inner diameter DIAL GAUGES
@
Correct
-
Correct
FSOOZO
l Measuring a depth
Wrong Correct
FSOO21
MICROMETERS
Put the anvil onto an object at a right angle and
turn in the spindle until it comes into contact with
the object. Rotate the ratchet stop until there are
two or three idle rotations, then read the
measurement.
When reading a measurement, keep your eyes at a
right angle to the graduation on the sleeve.
To turn back the spindle, rotate the thimble with
your fingers.
Correct Wrong
FSO022
When storing a micrometer, leave a slight clear-
ance between the anvil and the spindle.
Carefully put the gauge contact-point on a surface
to be measured to protect the delicate gauge
against shock.
Set the zero-point of the gauge with care to keep
the movement of the contact-point within its
stroke during measurement.
Careless setting of the zero-point may cause the
spindle to retract or extend to its limit, thus
making measurement impossible.
The measurements ‘of the dial gauge are
accompanied by relatively large errors because
minute variations of the contact-point (and
accompanying errors) are indicated by the dial
pointer through an expanding mechanism using
gears. The reliability of eye measurements can not
be assured below the minimum unit on the scale.
Measuring protrusions, depressions or steps
Set the zero-point so that vertical movement of
the probe does not exceed its stroke limits, and
slide the base of the gauge on a fiat surface.
FSO023
Measuring bending
Read the Total Indicator Reading (T.I.R.) while
moving the object back and forth or vertically.
Turn the object one complete rotation and read
the difference between the maximum and
minimum indications of the gauge pointer.
00-l6

Measuring end play, looseness or deviation l Measuring gear backlash
FSO025
Read the T.I.R. while moving the object back and
forth or vertically.
Measuring face runout or radial runout
Radial runout
FSOO26
1) Read runout at six or more positions during one
complete rotation of the object.
2) At the start of each measurement, set the zero-
point at the middle of the assumable range of
the spindle movement. Be careful not to con-
fuse positive and negative readings of runout.
‘)
When the pointer is
to the left of “0”
_
+
3) When measuring face runout, place the
contact-point on the object along a circle 2 or 3
mm smaller in diameter than the outside diame-
ter of the object.
Lever and fulcr
dial gauge
1) Fully mesh one of two gears and place the dial
gauge contact-point on a tooth of the other
gear. Swing the free gear within the limits of its
play in the rotational directions, and read the
T.I.R.
2) Use of the lever and fulcrum type dial gauge is
recommended for this purpose as the contact-
point placed on the gear is moved tangentially
to the gear pitch circle.
3) The lever and fulcrum type dial gauge is suitable
for use in a narrow space or for a special
measurement which requires placing the
contact-point on an object at an angle to the
spindle of the gauge.
Since the contact-point of this type of gauge
has a very narrow measuring range (usually 3
mm or less), the contact-point should be care-
fully checked for contact with the object during
measurement.
CYLINDER GAUGES
l Install a contact-point having a length approxi-
mately equal to the cylinder bore to the measured
on the cylinder gauge. Set the zero-point of the
test indicator to the bore diameter of the standard
cylinder measured with a reference ring gauge or
a micrometer.
Contact-point

Measuring point
FSO028
00-17

PARTS CHECKING INSTRUCTIONS
l Insert the gauge into the bore to be measured and
read the minimum indication of the test indicator
while giving swings to the gauge about the tip of
the detachable rod used as the fulcrum.
l When the minimum reading is obtained on the
right side of the zero point of the test indicator,
and the reading to the standard value to which the
zero point is set.
When the minimum reading is obtained on the left
side of the zero point, subtract the reading from
the standard value.
PARTS CHECKING INSTRUCTIONS
l Check disassembled parts to see if they are reusa-
ble or need repair. If the part failed due to an exter-
nal source, determine the cause and correct
before assembly.
1. GENERAL PRECAUTIONS
l Visually inspect parts for cracks, pitting, cor-
rosion, scoring, ridging etc. To ensure proper
inspection, every part should be clean before
inspection.
l If the cause of the defect can be found, it will be a
great help to analyze the part condition; whether
the defect will progress or not, and the possibility
of future trouble.
Knowing the cause of the defect, the service man
can give good advice to the customer to prevent
him from having the same trouble again.
l Visual inspection can not find minute or hidden
damage. Other methods of inspection are as
follows;
a) Water-pressure or air-pressure test
b) Color check or magnetic damage test
2. CRACKS
3. PITTING
1) Pitting by cavitation
In most cases, cavitation is accompanied by
chemical corrosion. After removing rust or
scale, carefully inspect the depth of pitting.
l When the pitting can not be repaired within the
allowable limit, replace the part.
l If pitting is not deep, resurface the part after
removing the rust and scale.
2) Pitting due to removal of surface
l If ball bearing is pitted, replace it.
l If more than l/3 of the contact face is pitted,
the part should be replaced.
l If pitting is not serious, resurface the part.
l If the part is found to be cracked by visual
inspection, it should be replaced or repaired.
l If the length or depth of crack exceeds 113 of the
thickness of the part, it should be replaced instead
of repaired.
l A part having an internal crack should be replaced.
00-l 8

PARTS HANDLING
PARTS HANDLING
1. OIL SEALS
1. Direction
Be careful to install the oil seal with its lips facing
in the proper direction, as shown in the figure
below.
Oil pressure side
Main lip &.t lip
FSO029
2. Inspection prior to installation
1) Keep the oil seals free from dust, rust and
scratches.
Take special care to prevent rust or scratches
on the lips.
2) To check the oil seal lip for smoothness, gently
slide a wire across its surface. If the wire
catches, replace the oil seal with a new one.
+ Make sure that the wire used for this test
does not scratch the lip surface.
3) Do not use the oil seal on a shaft where it
would come into contact with rust or scratches
on the shaft surface.
4) When removing the oil seal, take care not to
damage the housing or shaft surfaces.
3. Installing the oil seal
1) Coat the surface to which the oil seal is to be
applied with a lubricant or grease.
+ If the lip should double over as the oil seal is
being fitted over the shaft, return it to its
proper place by rotating the shaft and
pulling the oil seal slightly backwards.
2) When installing an oil seal on a shaft machined
with a keyway, splines, or threads, use a
suitable jig to protect the lip.
3) Use a suitable press to press fit the oil seal into
the housing.
. When installing the oil seal flush with the
housing surface.. .
Oil seal nominal outside
FSO031
. When installing the oil seal inside the
housing..
Oil seal nominal outside diameter
Oil seal nominal outside diameter + (0.5 - l.O)mm
- (0.5 - l.O)mm I I
t-L-7
Oil seal nominal outside diameter
- (0.5 - l.O)mm
FSO032 FSO033
4) After press-fitting the oil seal, check that it has
not been installed at an angle to the housing.
Max. permissible oil seal slant
(H, - HI)/2 S l/400
FSO034
Lip protectton jig
FSOO30
00-l 9.

PARTS HANDLING
4. Applying grease to the lips
Before installing an oil seal, coat it with grease
according to the following procedure to prevent
friction from burning the seal surfaces while the
machine is being started.
1) Single-lip oil seal
Place a flat, uniform coating of grease on the
surface away from the sealing surface.
‘Grease
FSO035
2) Double-lip oil seal
Coat the entire surface between the two lips
with grease in the manner shown in the accom-
panying figures.
Grease Grease
FSO036
5. Applying adhesives
Take special care when applying adhesives. to the
outer surface of oil seals. Adhesive on the surface
of the lip or shaft leads to oil leakage.
* Since any adhesives on the surface of the press
jig will soon transfer to the oil seal lips, clean
the jig before use.
2. FLOATING SEALS
1. Handling floating seals
1) Keep each pair of floating seals bundled
together with tape to avoid mix-ups when they
are reinstalled.
2) Discard the old O-rings. Always use new ones
when installing the floating seals.
3) Replace a floating seal if its contact surface is
rusted.
2. Installing floating seals
1) Remove all rust and dust from the mounting
surfaces of the seal. Use sandpaper to remove
any rust that might come into contact with the
O-ring.
2) When installing the floating seal, coat the
mounting surfaces with oil. Then install the
O-ring, taking care not to twist it.
* Do not coat the O-ring with oil.
* The floating seal has been correctly installed
3)
4)
5)
if the seal ring rotates.
After installing the O-ring and seal rings in both
housings, mate the two together.
I Housing
Seal ring
FSO037
An installer is recommended for inserting the
O-rings.
t Using a screwdriver or other pointed object
risks scarring the O-ring.
Attempting to mate the two housings together
without the O-rings and seal rings in place can
damage the O-rings and lead to oil leakage.
O-ring
I Housing
Seal ring
FSO038
00-20

PARTS HANDLING
3. O-RINGS 4. GASKETS
1. Handling 1. Handling gaskets
1) Discard any O-ring that has been in storage too I) Always replace packings, gaskets and copper
long or has hardened. packings with new ones.
2) Use only the O-rings prescribed for the part in
the PARTS BOOK. This is especially important
for those rings used with high-temperature
engine parts, where heat-resistant and durable
materials such as silicon are required.
3) ALWAYS USE NEW O-RINGS.
2) Make sure that there are no scratches or burrs
on the contact surfaces of the gasket.
2. Installing gaskets
I) Make sure that the holes in the gasket match
those in the mating part.
2) Apply gasket sealant to the joints so specified
in the SHOP MANUAL.
2. O-ring types
KOMATSU O-rings are marked with colored dots
as shown in the accompanying chart.
Marking Part Number Material Application
One blue spot 07000-0 ..... Nitrile rubber
Two blue spots 07000-1 ..... Nitrile rubber
One green spot 07000-3 ..... Fluorine rubbel
Two green spots 07000-2 Fluorine rubbel
One red spot 07000-4 .....
07000-5 ,...,
07000-6 .....
Nitrile rubber
Two red spots
Orange spot
Nitrile rubber
Silicon rubber
For
low-pressure
For
high-pressure
For
low-pressure
For
high-pressure
For
low-pressure
in cold weather
For
high-pressure
in cold weather
For
low-pressure
in hot weather
3. Inserting O-rings
After coating the O-ring with oil, insert carefully
so as not to damage it. Silicon rubber O-rings
require special care since they tear easily.
3. Precautions for using liquid gasket
1) Remove all scratches, dirt, paint, grease and old
gasket sealant before applying a new coat.
2) Coat the specified area evenly and let dry for
several minutes.
3) Assemble the mating parts when the gasket
sealant is stickly to the touch.
5. BEARINGS
1. Handling bearings
1) Shield the bearings from dust and dirt; even
the tiniest speck rapidly accelerates wear.
+ Leave the bearings in their protective
packaging until just before they are to be
installed.
2) Protect a bearing from excessive force and
shocks.
* Never dry a bearing with compressed air
after cleaning.
2. Installing bearings
I) Never drive a bearing onto a shaft by pounding
on the outer race or into an opening by
pounding on the inner race. Such pounding
produces dents in the tracks in the races.
2) When a bearing must be fitted onto a shaft
with some interference, press-fit the inner race
with the jig shown in the accompanying figure.
Jig
Press fit
FSO039
00-2 1

PARTS HANDLING
6. PRESS FITTING BUSHINGS
3)
4)
If the shaft of opening has considerable inter-
ference, heat the bearing before installing.
* Do not heat above 120°C.
When a non-separable bearing must be fitted
with interference for both races, press-fit with
the jig shown in the accompanying figure.
I I
Jig
Press fit
FSOO40
5) Thoroughly coat the bearing with oil before
installing.
6) Install the bearing, spacer or washer with its
chamfered surface facing the step on the shaft.
aCorrect
FSO041
Do not drive in a bushing directly with a hammer.
Use a press so that pressure is uniform over the
entire circumference.
1) If no press is available, hammer in the bushing
using a driving tool so that the force is
distributed evenly.
2) If the bushing has an oil hole, bring the hole into
exact alignment with the oil hole in the housing.
Rear face of
To injection
FSO043
3) When a bushing has been removed, remove all
burrs and foreign matter from the mounting
hole, and then clean.
7. REMOVING SNAP RINGS
I) Use snap ring pliers to remove or install snap
rings. Do not overexpand them-especially the
smaller ones.
2) After installing, check to make sure that the
snap ring is firmly in place within its groove.
00-22

PARTS HANDLING
8. HYDRAULIC PIPING 2. Installing the hydraulic piping
B Precautions for servicing the work equip-
ment hydraulic system
I) Lower the work equipment to the ground and
turn off the engine.
2) Loosen the oil filler cap to relieve pressure in
the hydraulic oil tank.
3) Operate the control levers 2 or 3 times to
eliminate hydraulic pressure remaining in the
piping to be disassembled.
4) Support the work equipment on a stand to
prevent it from falling when the piping is
removed and the hydraulic pressure is released.
1. Removing the hydraulic piping
1) Disconnect hydraulic tubes from hoses or other
tubes by holding the nut on the spigot (the
male side of the joint) with a wrench while
loosening the one on the socket (the female
side).
FSO044 7)
2) Seal the ends of the disconnected tubes and
hoses and the oil ports to the hydraulic
equipment with blind plugs to keep out foreign
matter. For the same reason, seal the ports of
the hydraulic tank with adhesive tape.
3) Have appropriately-sized containers under-
neath to catch the hydraulic fluid that will flow
out when the piping is disconnected. Clean up
all spills immediately.
4) When working under the machine, position
yourself out of the way of the oil shower.
5) Tag the ends of all piping removed as well as
the ports to which they were attached.
I)
2)
3)
4)
5)
6)
Thoroughly clean each piece of piping with a
suitable detergent (for example, light oil,
kerosene, trichloroethane) and remove all
traces of detergent with compressed air.
Repair the sealing faces or, if the scratches and
dents are too large, replace.
Do not use gasket sealant for hydraulic piping!
Install the piping so that alt the identification
tags match.
When a pipe must be joined at both ends,
tightening only one end at a time may make it
too short. First fit both ends by hand and then
tighten the ends by turns. (See figure.)
Tighten gradually and alternately
the both ends.
FSO045
To ensure tight-fitting seals, tighten the nuts to
80% of the specified torque, loosen 90°, and
then tighten to the full torque.
After completing all connections, run the
engine at idling speed and operate all the
control levers of the hydraulic attachments.
Then check the oil level in the hydraulic tank
and add oil as necessary.
00-23

PARTS HANDLING
3. Handling high-pressure hoses
I) Do not try to shorten the hose. A hose shorter than the specified length is subject to the defects shown in
the accompanying figures.
Shorting under pressure increases the tension.
/
FSO046
Too sharp a bend damages
FSO047
2) Make sure the hose is not twisted after it is installed.
The letters printed on the hose soon reveal any twists.
FSO048
3) Similarly, the hose must not twist as it moves.
FSO049
Improper connection causes the hose to twist as
the pipe moves.
FSOO50
4) The last figures on this page are examples of poor connections.
FSO05 1
Rubbing
e must have sufficient play
it to contract under pressure
FSOO52
FSO053
00-24

PARTS HANDLING
4. Handling hoses with self-seal couplings
1) Do not attempt to connect or disconnect or
coupling without first relieving the internal
hydraulic pressure.
* The gushing hydraulic fluid will not only soil
the surroundings, but the high flow rate may
also damage the O-ring of the coupling.
2) Never use a hammer to tighten or loosen a
coupling.
* Such sharp blows can deform the coupling,
leading to oil leakage or cracking of the
coupling.
3) Protect the disconnected piping from the
intrusion of dust and dirt ! If it is to remain
disconnected for some time, seal by con-
necting to another coupling or by fitting a dust
cap or a blind plug to each end.
“I.4 ”
FSOO54
During storage
FSO055
5. Handling split flanges
1) Follow the bolt tightening sequence given in
the figure.
2) Press the two halves completely together and
tighten them uniformly. If they are not held
tightly together, they will separate by a
distance equivalent to the clearance between
the fastening bolts and their holes, forming a
pathway for oil leakage.
FSO057
6. Using sealing tape
1) To prevent oil leakage, wind sealing tape
around the tapered thread before inserting the
plug into the plug hole.
2) Wrap all but the first 1.5 threads at the tip and
then force the tape into the threads with a
fingernail. Wind the tape in the same direction
as the threads.
ave 1.5 threads bare.
FSO058
FSO056
00-25

PARTS HANDLING
9. SPRING WASHERS
Judging suitability
I) Discard the spring washer if the overlapping
portion is worn or damaged.
FSO059
2) Discard if the distance P is more than 2t/3.
FSOO60
10. SPRING (ROLL) PINS
Handling spring pins
1) A spring pin performs somewhat better when
the split is placed facing the load instead of at a
right angle to the load.
FSOO61
ll.PUMP
I) After assembly and before installation, fill the
pump with oil through the intake port to
provide initial lubrication.
2) Before installing the pump, turn the drive
shaft by hand to make sure that it turns
smoothly without any catching.
*
Inlet
I f
-
J
FSO062
3) Test run the installed pump and check for
unusual noises and leakage.
12. SEAL RINGS
I)
2)
3)
4)
Seal rings are very delicate, so handle and
store carefully.
Do not reuse rubber seal rings.
Avoid excessive stretching when fitting a seal
ring over a shaft; it decreases the ring’s
performance.
Remove all sharp edges before fitting a seal
ring into a slot on an abutment.
Check for sharp edges and scratches
Seal ring
00-26

A Heavy parts (25 kg or more) must be lifted
with a hoist etc. In the Disassembly and As-
sembly 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:
l 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
I) 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
30 10.0
40 18.0
50 28.0
60 40.0
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 from the middle portion of the
hook.
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% 88% 79% 71% 41%
FSOO64
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
Q
( 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.
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”.
30" 60" SO' 120" 1500
Liftingangle : cy
FSO065
00-27

. Approximate reduction of allowable load for
wire ropes at various hanging angles.
Hanging angle I Reduction in %
91” - 120” I 50%
a Hanging angles should not exceed 150”.
5) When hoisting several parts as a unit, be
careful not to allow any part of the unit to fall.
Use a suitable container when hoisting many
small parts at a time.
6) Select the most suitable sling device when
hoisting a specially-shaped object.
Cylinder
head
7) When using a hoist to turn over a heavy part,
observe the following instructions:
l Clear as much of the area surrounding the
part as possible.
. When turning the part over, take special care
to prevent the ropes from slackening and the
part from slipping when the center of gravity
changes.
. Gradually slacken the wire ropes after
making sure that the part is completely
turned over.
Slackening the ropes before complete
turning of the part may cause the part to fall
back to its original position.
3. Hanging bolts
02P-02 I
Part Number d Pitch L
Allowable
load (kg)
04530-0815 8 1.25 15 80
04530-l 018 10 1.5 18 150
04530-l 222 12 1.75 22 220
04530-l 628 16 2.0 28 450
04530-2030 20 2.5 30 630
04530-2438 24 3.0 38 950
04530-3045 30 3.0 45 1500
04530-3655 36 3.0 55 2300
04530-4625 46 3.0 25 3400
04530-487C 48 3.0 70 4500
* The allowable load in the table means the
maximum static load which the bolt can
withstand. The values of allowable load given
in the table should be reduced, taking the
necessary safety factors into consideration, as
these bolts will be subjected to shocks during
actual hoisting operation. The allowable loads
in the table are applicable to the bolts slung
vertically from a hoist.
00-28

ml4
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”.
Thread diameter Width
of bolt across flat
(mm) (mm)
0 7
kgm
z
0
Nm
6 10 1.35*0.15 13.2+ 1.4
8 13 3.2 a0.3 31.422.9
10 17 6.7 20.7 65.7t6.8
12 19 1 1.5 f 1 .o 112k9.8
14 22 18.Ok2.0 177*19
16 24 28.523 279*29
18 27 39*4 383239
20 30 56?6 549t58
22 32 76a8 745278
24 36 94.5&10 927+98
27 41 135+15 1320&140
30 46 175220 1720&l 90
33 50 225&25 22102240
36 55 280*30 2750+290
39 60 335235 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): 1 Nm f 0.1 kgm
2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Threatf difi;eter
(mm)
10
12
16
Width
across flats
(mm)
14
17
22
Tightening torque
kgm Nm
6.7kO.7 65.7k6.8
11.5*1 11229.8
28.523 279+29
00-29

3. TIGHTENING TORQUE FOR NUTS OF FLARED
Sealing surface
Use these torques for nut part of flared.
Thread diameter
of nut part
(mm)
14 19 2.5 F0.5 24.5 t4.9
18 24 522 49tlS.6
22 27 812 78.5 k 19.6
24 32 1423 137.3t29.4
30 36 1823 176.5t29.4
33 41 2Ok5 196.1 r+49
36 46 2525 245.2*49
42 55 3oi5 294.2a49
Width across flats
of nut part
(mm)
T
FSOO68
Tightening torque
kgm
COATING MATERIALS
Nm
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Nomenclature Komatsu code Applications
Adhesives
LT-1A
LT-1B
LT-2’
Used to apply rubber pads, rubber gaskets, and cork plugs.
Used to apply resin, rubber, metallic and
non-metallic parts when a fast, strong seal is needed.
Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-3
Provides an airtight, electrically insulating seal.
Used for aluminum surfaces.
Liquid gasket
LG-1 Used with gaskets and packings to increase sealing effect.
LG-3 Hea;t-resistant gasket for precombustion chambers and exhaust piping
I LG-4
I
Used by itself on mounting surfaces on the final drive and transmission cases
(Thickness after tightening: 0.07 - 0.08 mm)
Antifriction compound
(Lubricant including
molybdenum disulfide)
Grease
(Lithium grease)
LG-5
LM-P
G2-LI
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
fittings in hydraulic circuits of less than 50 mm in diameter.
Applied to bearings and taper shafts to facilitate press-fitting and to
prevent sticking, burning or rusting.
Applied to bearings, sliding parts and oil seals for lubrication, rust
prevention and facilitation of assembling work.
Vaseline - Used for protecting battery electrode terminals from corrosion.
‘LT-2 is also called LOCTITE in the shoo manuals
00-30

ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Nominal
number Number
strands
Copper wire
_ Cable O.D. Current rating Applicable circuit
Dia. of strands Cross section (mm) (A)
(mm) (mm?
01 11 0.32 0.88 2.4 12 Starting, lighting, signal etc
02 26 0.32 2.09 3.1 20 Lighting, signal etc.
05 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 j7a Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Instrument Other
Code 6 W R G Y L
1 Primary
Color Black White Red Green Yellow Blue
2
3
4
Auxiliary
BW
I WR
I RW
I I
Black & White White & Red Red &White
Black & Red 1 White &Blue 1 Red &Yellow Green &Yellow Yellow & Green Blue &Yellow
Green &White Yellow & Red
GR YB
Green & Red Yellow & Black Blue & Red
GY
YR
YG
LW
Blue & White
LR
LY
Code
Color
Code
Color
- WY RG GB YL LB
- White &Yellow Red & Green Green & Black Yellow & Blue Blue &Black
- WG RL GL YW
- White &Green Red & Blue Green &Blue Yellow &White
00-3 1

WEIGHT TABLE
a This weight table is a guide for use when transporting or handling components.
Engine assembly 1453
Radiator assembly 285
Steering cylinder (I piece)
Brake (1 piece)
(Unit: kg)
47
170
Torque converter assembly
I
193 Hydraulic tank
Transmission assembly
I
980 Main control valve
I
90
Damper 91 Lift cylinder (I piece) 279
Center drive shaft 33 Dump cylinder 283
Front drive shaft
I
44 Engine hood
I
43
Rear drive shaft
I
42 Front frame 2486
Front axle assembly
Rear axle assembly
2028 Rear frame 2012
1776 Bucket link (with bushing) 94
Front differential assembly
I
288 Tilt lever (with bushing)
I
457
Rear different: assembly 1 1::
Planetary carrrer assembly (I prece)
Planetary hub assembly (I piece)
Axle pivot (Rear axle) 92 (I 19) Fuel tank
I
328
Lift arm (with bushing) 1996
Bucket with teeth 2351
Counterweight 880
Wheel (I piece)
I
240 Battery (I piece)
I
53
Tire (1 piece) 421 Operator’s seat 40
Steering valve 55 Floor plate 131
WA500- 1
0°if3

TABLE OF OIL AND COOLANT QUANTITIES
RESERVOIR
Engine oil pan
Brake
Transmission case
Hydraulic system
AMa
(Front and rear)
Fuel tank
Cooling system
TKIND OF
AMBIENT TEMPERATURE CAPACITY (PI
FLUID
-22 -2 14 32 50-30 -10 0 10 ;: :: ‘g$E‘g Specified
~~~~~~~~~ii.i~~~~~~~~~.:<.:.:.y..:.:.:<.:.:<.>,,,&,.,,,,,......,,..,,._(1.*,,n .,.:,,.,............:.:.:.:.:.:.:c:<.:;:.:.:.,, ,,,,.,.,.,,,,.,,,,
Engine oil
Diesel fuel
Water Add antifreeze
SW NOTE (4) each 75
435
80
ASTM: American Society of Testing and Material
SAE: Society of Automative Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
NOTE:
(I)When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic mainte-
nance hours described in this manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Fuel sulphur content
Changeinterval of oil
in engine oil pan
0.5 to 1.O%
I
Above 1.O%
I
Refill
28.5
2.4
62
150
each 75
(2) When starting the engine in an atmospheric tem-
perature of lower than O”C, be sure to use engine
oil of SAEl OW, even though an atmospheric tem-
perature goes up to 10°C more or less in the day
time.
(3) Use API classification CD as engine oil and if API
classification CC, reduce-the engine oil change in-
terval to half.
(4) For axle oil, use only recommended oil as follows.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
* It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
If noise comes from the brake, it is no problem of
durability.
o”634
WA500- 1

ENGINE
11STRUCTURE AND FUNCTION
Engine mount ............................. 11-2
Radiator .................................. 11-3
Fuel tank and piping ........................ 11-4
Engine control ............................. 11-5
WA500- 1 11-l

ENGINE MOUNT
Section A - A Section B - B
425FOO7
. The engine is mounted separately from the torque
converter and transmission.
. Both front and rear have rubber mounts.
11-2
1. Rear mount
2. Front mount
WA500- 1

RADIATOR
Section A - A
5 ‘4
1. Radiator
2. Coolant level sensor
3. Fan guard
4. Torque converter oil cooler
5. Hydraulic oil cooler
A. Coolant inlet port
B. Coolant outlet port
C. Wind
425FOO8
Specifications
Core type: G7 type
Total heat dissipating area: 89.9 cm2
Cross-sectional area of water tubes: 193.8 cm2
WA500- 1 11-3

FUEL TANK AND PIPING
The fuel level sensor is installed in the fuel tank.
11-4
1. Fuel level sensor
2. Drain valve
3. Injection pump
WA500- 1

ENGINE CONTROL
F42101002
WA500- 1
1. Accelerator pedal
2. Accelerator cable
3. Injection pump
1l-5

ENGINE
12 TESTING AND ADJUSTING
Standard value table ...................
Tool list for testing and adjusting ...........
Adjusting valve clearance ................
Measuring compression pressure ...........
Testing and adjusting fuel injection .........
Measuring blow-by pressure ..............
Testing and adjusting belt tension ..........
Measuring exhaust gas color ..............
Measuring engine oil pressure and temperature . .
Adjusting fuel cut solenoid ...............
Measuring accelerator pedal operating force
12- 2
12- 3
12- 4
12- 5
12- 6
12- 8
12- 9
12-10
12-l 1
12-12
and operatin angle .................. 12-13
* The following precautions are necessary when using the Standard Value Tables to make judgement during trouble-
shooting or during testing and adjusting.
1. The values in these tables are based on the values for new machines leaving the plant, so they should be used
as target values when repairing or when estimating wear after a period of use.
2. The standard values in these tables for judgement when troubleshooting are estimated values based on the
standard values for the machine when shipped from the plant, and on the results of various tests.
Therefore, they should be used as reference in combination with repair and operating records when making
judgements.
3. These standard value tables must not be used for standard values when judging claims. In addition, do not use
these values alone to make simple judgements.
WA500- 1 12-1
0

STANDARD VALUE TABLE
Cate-
slow
Item
E
:
Engine speed
E
b
‘=
a” I-----.Necessary starting speed
6 Intake resistance
z
>0l Exhaust temperature
5
2
!z Exhaust gas color
0
:
Oil pressure
E
(entine water tempwrature
r green range
t
5.-
5 +
Oil temperature
i 1 Oil consumption ratio
‘rg
Coolant temperature
E
t;
?;
r” Thermostat function
.-
5
s
Fan belt tension
(Tension pulley-
I
i / Operatinganglea
0
z Stopper height L,
&
z
s
Engine
Condition
High idling speed
Unit
rpm
KOMATSU S6D140-1
Standard value Permissible value
2250 - 2350 -
660 - 720
I -
All speed (intake air temp. 2O’C
At abrupt acceleration
At high idling
Intake valve
Exhaust valve
Oil 40temperature - 60°C
(engine speed: 160 200 rpm)-
OC
Bosch index
Bosch index
mm
mm
kg/cm’
Max. 650 Max. 650
Max. 4.0 5.0
Max. 1.O 2.0
0.43 -
0.80 -
Min. 32 22
At high idling
At high idling
At low idling
Whole speed range
(inside oil pan)
mmH,O Max. 100 200
kg/cm’ 3.5 - 5.5 2.0
SAE30
kg/cm’
Min. 1.0 0.7
SAEIOW Min. 1.O 0.7
OC 80- 110 120
Max. 0.5 1.o
250* 10 250 c 10
27 27 * 1
70 - 95 100
At continuous rated horesepower
(proportion to fuel consumption)
Nozzle tester
Before top dead center
Whole speed range
(at engine outlet)
%
kg/cm2
degree
“C
74.5 - 78.5 74.5 - 78.5
90 90
9.5 - 10.5 9.5 - 10.5
6
II I I
kg 8-9 Max. 13.5
o1 45 os 30 -
15-25 -
14-24 -
136 - 146 -
12-2
0
WA500-1

TOOL LIST FOR TESTING AND ADJUSTING
NO Tool Name Part No. I RemarksTesting and measuring item
Digital display 60-19999 rpm
xxEngine speed Tachometer
Battery specific gravity2
3
Battery coolant tester
Coolant freezing temperature
4
Water temperature, oil temper-
ature, intake temperature
799-l 01-6000
Thermistor
temperature gauge
5 Exhaust temperature
Lubricating oil pressure
T0 - 10 kg/cm’6
7 Fuel pressure
799-203-2002 28
9
Intake pressure, Engine pressure
exhaust pressure measuring kit
Blow-by pressure 0 - 1000 mmH,O
10
11
12
Compression pressure
Blow-by pressure
Compression gauge
Blow-by checker
13
14
15
Valve clearance Feeler gauge 795-l 25-1210 0.43, 0.80 mm
799-2 1O-9000
Discoloration 0 to 70% standard color
(Discoloration %x l/10 = Bosch index)
Exhaust gas color
Fuel on water mixed in oil
Handy smoker checker
Engine oil checker 799-201-6000
Water content 0.1%. 0.2%
in standard sample
16 Coolant quality Water quality tester 799-202-7001 PH. nitrous acid ion concentration
17 Leakage from cooling system Cap tester 799-202-9001 0 - 2 kg/cm’
18
Fuel injection pressure
Nozzle injection condition
Nozzle tester
Commercially
available
0 - 300 kg/cm’
19 Electrical circuit Tester
Commercially
available
Current, voltage, resistance
79A-262-0020 Commercially available 0 - 25 kg20
-
Accelerator pedal force Push-pull scale
n!
Qf
n!
Qt
When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, insert the safety pins
and block the tires.
When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
When checking the water level in the radiator wait for the water to cool. Do not remove the radiator cap while
the water is hot. Boiling water may spurt out.
Be careful not to get caught in rotating parts.
12-3
0
WA500- 1

ADJUSTING VALVE CLEARANCE
* Condition: Engine is cold.
* Adjust clearance between crosshead and rocker lever
as follows.
Unit: mm
I Intake valve Exhaust valve
Cold 0.43 0.80
Special tool
Part No. Part Name Q’ty
A 795-l 25-1210 Feeler gauge 1
Cylinder No. 1 2 3 4 5 6
I, I, I, I II I II
I-- Intake valve l l 0 0 0 0
Exhaust valve l 0 l 0 0 0
4. To adjust, insert tool A between rocker lever (3)
and crosshead (4) and turn adjustment screw (5)
until clearance is a sliding fit. Then tighten lock
nut (6) to hold adjustment screw in position.
Remove cylinder head cover (1).
Rotate the crankshaft in the normal direction to
align pointer (2) with the 1.6 TOP mark on crank-
shaft pulley. When rotating, check the movement
of the valves. When the pointer is in line with the
1.6 TOP mark, No. 1 cylinder should be at com-
pression top dead center.
When No. 1 cylinder is at compression top deal
center, adjust the valve marked 0.
When No. 6 cylinder is at compression top dead
center, adjust the valves marked 0.
m Lock nut: 6.0 ? 0.6 kgm
5. Next, rotate crankshaft one turn in the normal di-
rection and adjust the valve clearance of the re-
maining valves marked 0.
* After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn crank-
shaft 120” each time and adjust the valve clear-
ance of each cylinder according to the firing
order.
- Firing order: l-5-3-6-2-4
* After tightening the lock nut, check the clear-
ance again.
615OF201
12-4
0
WA500- 1

MEASURING COMPRESSION PRESSURE
* Measurement condition
* Coolant temperature: Inside operating range.
* Engine valve clearance: Standard value.
* Engine speed: 160 to 200 rpm
Unit: kg/cm*
Item Standard value Permissible value
Compression
pressure
Min. 32 22
Special tools
Part No. Part Name I O’tv
A 1 795-502-I 204 / Compression gauge I 1
4 / 795-502-I 510 1 Adapter I 1
A, 1 795-502-I 520 / Plate I 1
8 I 799-203-8000 1 Tachometer I 1
* If performance tests or troubleshooting shows that
the piston, piston ring or cylinder liner may be worn,
pressure.measure the compression
a
When measuring the
careful not to touch
muffler, or to get caugh
compression pressure, be
the exhaust manifold or
t in rotating parts.
1. Adjust valve clearance.
* For details, see ADJUSTING VALVE CLEAR-
ANCE.
2.
3.
Warm up engine (oil temperature 40 to 6O’C).
Remove nozzle holder assembly.
* For details, see REMOVAL OF NOZZLE HOLD-
ER ASSEMBLY.
4.
5.
6.
Install tool A, AI and Az in mount of nozzle holder
assembly, and connect pressure gauge.
Set engine tachometer B in position.
Disconnect fuel CUT-OFF solenoid valve connector.
Crank engine with starting motor and measure com-
pression pressure.
* Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
* When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
* Installing the nozzle holder assembly after measur-
ing the compression pressure.
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
WA500- 1

TESTING AND ADJUSTING FUEL INJECTION TIMING
- Coolant temperature: Inside operating range.
Unit: degree
Fuel injection
timing
B.T.D.C. 27
/
27 + 1
TESTING FUEL INJECTION TIMING
1.
2.
3.
4.
5.
*
Disconnect fuel injection pipe (1) of No. 1 cylinder.
Remove delivery valve holder (2), then remove
delivery valve (3) and spring (4). and install deliv-
ery valve holder (2) again.
Place accelerator pedal at FULL position.
Operate priming pump and rotate crankshaft
slowly in normal direction. Check point where
fuel stops flowing from delivery valve holder (2).
Check that 27” I.J. line on damper (5) and pointer
(6) are aligned at point where fuel stops flowing.
* BEYOND injection timing line:
Timing RETARDED
* BEFORE injection timing line:
Timing ADVANCED
If the test shows that the fuel injection timing is
incorrect, adjust as follows.
12-6
0
WA500- 1

ADJUSTING FUEL INJECTION TIMING
BY DELIVERY CHECK
6. Turn crankshaft back 30 to 40” from top dead
center.
7.
8.
Rotate crankshaft to align 27’ I.J. line on crank-
shaft pulley and pointer correctly.
Loosen nut (7) on the injection pump mounting
flange bolt, and rotate the flange on the pump
side little by little by operating the priming pump
(8) until no fuel flows out of the delivery valve
holder.
9.
IO.
11.
Tighten nut (7) in oblong hole of mounting flange
of fuel injection pump.
* After tightening the nut, check again that the
fuel stops flowing from the delivery valve holder
at the point where the pointer is aligned with
the line on the crankshaft pulley.
Remove delivery valve holder (2), assembly deliv-
ery valve (3) and spring (41, then install delivery
valve holder (2) again.
w Delivery holder: 3.3 f 0.2 kgm
Connect fuel injection pipe (1).
w Sleeve nut: 2.4 i 0.1 kgm
WA500- 1 12-7
0

MEASURING BLOW-BY PRESSURE
- Coolant tempe*ure: Inside operating range.
* Engine valve clearance: Standard value.
* Engine oil temperature: Min. 60°C
Unit: mmH,O
Blow-by
pressure I
Max. 100
I
Max.200
Special tool
Part No. Part Name O’ty
A 1 799-201-l 503 Blow-by checker I 1
Qf When taking measurements, be careful not to touch
the exhaust manifold or muffler, or to get caught
in rotating parts.
1. Measuring blow-by
When measuring the blow-by, warm the engine
up thoroughly.
Stop engine and install adapter of blow-by
checker on engine breather hose (1).
Connect adapter and blow-by A (0 to 500
mmH,O) to hose.
Run the engine at high idling and measure the
blow-by pressure.
2. Precautions when measuring blow-by
* The blow-by should be measured with the
engine running at rated output.
- When measuring in the field, a similar value
can be obtained at stall speed.
- If it is impossible to check at rated output
or stall speed, measure at high idling.
In this case, the blow-by value will be about
80% of the value at rated output.
* Blow-by may vary greatly according to the
condition of the engine, so if there is any ab-
normality in the reading, check for any prob-
lem related to defective blow-by, such as ex-
cessive oil consumption, defective exhaust
gas color, or early deterioration or contami-
nation of the oil.
12-8
0
WA500- 1

TESTING AND ADJUSTING BELT TENSION
TESTING AND ADJUSTING FUN BELT
TENSION
Unit: mm
Item
Standard Permissible
value value
I
Deflection of belt 6
. Testing fun belt tension
Check the amount the fan belt deflects when push-
ed with a force of approx. 6 kg at a point mid-way
between the fun pulley and tension pulley.
Use a scale to measure the amount the V-belt deflec-
tion.
. Adjusting fun belt tension
1) Loosen lock nut (I) of tension pulley.
2) Adjust the belt tension of adjusting bolt (2),
tighten lock nut of tension pulley.
Approx. 6 mm
TESTING AND ADJUSTING ALTERNATOR
BELT TENSION
Approx. 15 mm
Unit: mm
Item
Deflection of belt
Standard
value
15
Permissible
value
-
Testing alternator belt tension
Check the amount the alternator belt deflects when
pushed with a force of approx. 6 kg at a point
mid-way between the alternator pulley and water
pump pulley.
Use a scale to measure the amount the V-belt deflec-
tion.
Adjusting alternator belt tension
1) Loosen alternator mount bolt, nut (I) and bolt
(2) of adjusting plate.
2) Use a bar, rise alternator assembly and adjust
tension of belt (3), and tighten bolt (2) of
adjusting plate as first, tighten alternator
mount bolt, nut (1).
Alternator pulley
Approx. 6 kg
*
Water pump pulley
425F202
WA500- 1 12-9
0

MEASURING EXHAUST GAS COLOR
. Coolant temperature: inside operating range.
. Valve clearance: Standard value.
Unit: Bosch index
Item
Standard Permissible
value value
Exhaust
color
Acceleration
High idling
Max. 4.0
Max. 1.o
5.0
2.0
Special tool
I Part No. I Part Name O’ty
A
Commercially
available
Smoke meter 1
* When measuring the exhaust color, warm the engine
up thoroughly (oil temperature 6O’C).
1. Insert probe A rn outlet of exhaust pipe (I) and
0’
secure to exhaust pipe with clip.
2. Connect probe hose, connector hose of accelerator
switch and air hose
8
to smoke meter A.
* The pressure of the air supply should be under
15 kg/cm2.
3. Connect power cord to socket.
t Check that the power switch is OFF before
connecting the cord.
4. Loosen cap nut of suction pump and insert filter
paper.
5. Turn power switch ON.
6. Accelerate engine suddenly. At the same time, de-
press accelerator switch of smoke meter, operate re-
lief valve and catch exhaust gas color on filter paper.
7. Lay filter paper used to catch exhaust gas color on
top of unused filter papers (IO sheets or more)
inside filter paper holder, and read indicated value,
Qf When measuring the exhaust color, be careful
not to touch the exhaust pipe.
12-10
0
WA500- 1

MEASEURING ENGINE OIL PRESSURE AND TEMPERATURE
MEASURING ENGINE OIL PRESSURE
. Coolant temperature: Inside operating range.
Unit: kq/cm*
Oil pressure
High idling
Low idling 1 Min. 1.O I 0.7
Special tool
I Part No. I Part Name O’ty
A 799-203-2002
Engine pressure
measuring kit
nWhen measuring, be careful not to get caught in
rotating parts.
n ! Install and remove the plug and oil pressure
gauge with the engine stopped.
* Measure the engine oil pressure when the oil tem-
perature is at the specified temperature.
1. Disconnect connector of wiring (I), then remove
plug (2).
2. Install oil pressure gauge A (20 kg/cm2).
* Install the oil pressure gauge so that it is affect-
ed as little as possible by the engine vibration.
3. Start engine and measure oil pressure.
MEASURING OIL TEMPERATURE
. Coolant temperature: Inside operating range
Oil temperature 80-llO°C 120°c
Special tool
Part No. Part Name Q’ty
A I 799-l016000 Thermister temp. gauge
Al I 799-l 01-6140 sensor
1. Remove dipstick (1).
2. Insert sensor A, of thermistor temperature gauge in
dipstick guide.
Connect sensor to thermistor temperature gauge A
and measure temperature of oil in oil pan.
WA500- 1 12-11
0

ADJUSTING FUEL CUT SOLENOID
1. Adjust rod 15) while pulling rod (5) in the running direc-
tion so that there is clearance of 0.4 kO.1 mm between
stop lever (4) and stopper (7).
2. Turn on the engine starting key and confirm that the
solenoid has a stroke of 12 mm and clearance of 0.4 *
0.1 mm.
3. After turning on and off the key two or three times,
reconfirm that solenoid works smoothly and engine runs
or stops completely.
* If the solenoid does not work smoothly, solenoid
coil burns in the cause of excessive current or
flywheel horsepower downs in the cause of dropp-
ing fuel injection volume.
v;
is
_1
IL
4
-.
621OFlll
12-12
0
WA500- 1

MEASURING ACCELERATOR PEDAL OPERATING FORCE
AND OPERATING ANGLE
- Coolant temperature: Inside operating range.
Unit: kg
Operation force of
accelerator pedal
8-9 13.5
Special tool
Part No. Part Name a’ty
A 79A-262-0020 Push-pull scale 1
OPERATING FORCE
1. Measuring procedure
1) Put push-pull scale A in contact with the ac-
celerator pedal at point 150 mm from pedal
fulcrum “a”.
* The center of push-pull scale A must be in
contact with a point 150 mm from the pedal
fulcrum.
2) Start the engine, push the pedal in the direc-
tion of operation and measure the maximum
value when pushing from idling to the end of
the pedal travel (high idling).
Testing and adjusting
1) Stop the engine.
2) Disconnect the cable (1) at the bottom of the
accelerator pedal, and check that the linkage
(2) and ball joint (3) at the bottom of the pedal
move smoothly.
3) Connect the cable at the bottom of the pedal,
then disconnect at the connection for the
injection pump, and check that the cable (4)
moves smoothly.
* When carrying out this inspection, adjust
or replace parts as necessary. Measure the
operating force again and check that it is
within the standard value.
423F304
WA500- 1 12-13
0

OPERATING ANGLE OF ACCELERATOR PEDAL
1. Measuring procedure
1) Stop the engine.
2) Measure the operating angle q, a2, put the
angle gauge A in contact with the accelerator
pedal it is operated from low-idling and high
idling.
3) Measure installed length X of rod (1).
2. Adjusting procedure
1)
2)
3)
4)
5)
Remove cover under cab.
Loosen nut and adjust so that installed length
X of the rod (1) is within the standard value.
Loosen nut (2) and adjust bolt so that installed
height L1 of accelerator pedal stopper is
Loosen nut (3) and adjust bolt so that installed
height L2 of accelerator pedal stopper is
Adjust the length of the rod (4) so that the
injection pump governor lever contacts the
high idling stopper when the pedal is depressed
(high idling) and still tighten stopper bolt (3)
half turn.
423F305C
12-14
0
WA500- 1

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KOMATSU WA500-1 WHEEL LOADER Service Repair Manual SN：10001 and up