Komatsu wh609 1 telescopic handler service repair manual sn 395 f60001 and up

WEBM005700
WH613-1WH609-1
WH713-1 WH714-1
WH714H-1 WH716-1
TELESCOPIC HANDLER
MODEL
WH609-1
SERIAL NUMBER
395F60001 and up
WH613-1 395F60003 and up
WH713-1 395F70001 and up
WH714-1 395F70002 and up
WH714H-1 395F70003 and up
WH716-1 395F70004 and up

WH6 - WH7 00-1
CONTENTS
CONTENTS
Pagina
10. STRUCTURE AND FUNCTION ...................................................................................... 10-1
20. TESTING AND ADJUSTING ........................................................................................... 20-1
30. DISASSEMBLY AND ASSEMBLY................................................................................. 30-1
90. OTHER...................................................................................................................... 90-1

REMOVAL AND INSTALLATION
WH6 - WH7 30-15
ENGINE HOOD
ENGINE HOOD
Removal
1 -Lift the engine hood (1).
RKTA0330
1
2 -While supporting the engine hood, loosen and remove
the screws (2) retaining the hinges (3).
RKTA0340
3
2
3 -Remove the cotter pin (4), the backing washer, and dis-
connect the gas damper (5) from its support (6).
RKTA0350
4
5
6
4 -Lower the hood and place an anti-slip block (A) between
lower edge of hood and body; then, strap the hood and
connect it a hoist.
5 -Remove the hood (1). [*1]
RKTA0360
A

WH6 - WH730-16
ENGINE HOOD
Installation
• To install, reverse the removal procedure.
[*1]
1 -Adjust thepositionof thehood, ensuring thatthe lock as-
sembly (7) is centred in relation to the retaining hook (8).
RKTA0370
7
8
2 -Adjust the hinges vertically (3) to allow the closure seal-
ing strip (9) to evenly rest along the length of the hood.
RKTA0380
3
9
3 -Adjust the hinges (3) horizontally until full contact be-
tweenthesealingstrip(10)andtheengine-transmission
mount (11) is achieved.
RKTA0390
3
10
11

WH6 - WH7 30-17
AIR FILTER
AIR FILTER
Removal
1 -Unscrewand remove thecap(1) fromthe surge tank (2).
2 -Loosen and remove the screws (3), remove the surge
tank (2), and position the tank aside.
RKTA0400
1
3 2
3
3 -Loosen the clamps (4), (5) and disconnect the outside
airinlethose(7)andengineintakehose(8)fromthefilter
(6).
RKTA0410
4
5
6
7
8
4 -Disconnect the air cleaner clogging sensor connector
(9).
RKTA0420
9
5 -Loosen and remove the screws (10) together with wash-
ers and nuts and remove the filter (6).
Installation
RKTA0430
10
6

WH6 - WH730-18
TURBOCOMPRESSOR (only if equipped)
Removal
1 -Remove the engine hood.
(For details, see "ENGINE HOOD").
RKTA0361
2 -Disconnect the outside air inlet hose (2) from the air
cleaner (1).
RKTA0411
1
2
3 -Disconnect the hose (4) from the oil vapour bleed valve
(3) and remove the air cleaner-to-turbocompressor
hose (5).
RKTA0440
3
4
5
4 -Loosen the clamps (6) and remove the hose (7).
RKTA0450
6
7
6

WH6 - WH7 30-19
5 -Loosen and remove the three screws (8) and remove
the support (9).
RKTA0460
9
8
6 -Loosen and remove the screws (10) retaining the ex-
haust pipe (11).
RKTA0470
10
11
7 -Disconnect the exhaust pipe (11) and recover the gas-
ket (12).
RKTA0480
11
12
8 -Remove the turbocompressor following the instructions
given in the engine workshop manual (code
WHBMNEF000).
Installation

WH6 - WH730-20
EXHAUST PIPE
EXHAUST PIPE
Removal
• 1st Length
1 -Loosen and remove the screws (1) securing the pipe (2)
to the turbocompressor (3) (models with turbo engine),
or to the exhaust manifold (models with aspirated en-
gine).
a Models with aspirated engine:
replace the gasket between exhaust pipe and man-
ifold at each disassembly.
RKTA0471
2
1
3
2 -Loosenandremovethescrews(4)togetherwiththeirre-
spective washers, and remove the pipe (2).
a Replace the gasket between exhaust pipe and muf-
fler at each disassembly.
3 -Remove the pipe (1).
RKTA0490
4
2
4
• 2nd
Length
1 -Loosen and remove the screws (5) and remove the tail
pipe (6). [*1]
RKTA0500
6
5
2 -Loosen and remove the screws (7) securing the 2nd
length of the pipe (8) to the muffler (9).
a Replace the gasket between exhaust pipe and muf-
fler at each disassembly.
RKTA0510
7
8
9

WH6 - WH7 30-21
EXHAUST PIPE
3 -Loosen the screw (10) remove the retaining screw (11),
and remove the clamp (12).
4 -Remove the pipe (8).
RKTA0520
8
10
11
12
Installation
[*1]
a Before locking the tail pipe (6), adjust it until it is cen-
tred in relation to the 2nd length of the exhaust.

WH6 - WH730-22
GENERATOR – FAN BELT
Removal
1 -Loosen and remove the retaining screws and remove
the fan guard (1).
RKTA0530
1
2 -Loosen the screws (2) and (3); remove the screws (2)
and disengage the radiator (4) from the brackets (5).
RKTA0540
5
3
4
2
3 -Loosen the lower nuts (6) retaining the anti-vibration
supports (7).
RKTA0550
6
7
4 -Turn the radiator over and towards the rear of the ma-
chine to gain access to the fan retaining nuts (8) and
washers.
5 -Remove the fan.
RKTA0560
8
9

WH6 - WH7 30-23
6 -Remove the worn belt (10) and replace it by performing
the relevant procedures described in the engine work-
shop manual. [*1]
RKTA0561
10
Installation
[*1]
a Tension the belt by performing the belt tensioning
procedure described in the engine workshop man-
ual (code WHBMNEF000).

WH6 - WH730-24
RADIATOR-EXCHANGER ASSEMBLY
Removal
1 -Unscrew the cap (1) and drain the coolant liquid. [*1]
6 Coolant liquid: 20 l approx.
RKTA0541
1
2 -Loosen and remove the screws (2) retaining the clamps
(3).
3 -Disconnect the hose (5) connecting to the expansion
tank from the cap (4).
RKTA0570
3
4
5
2
3
4 -Disconnect and remove the engine air intake hose (6).
RKTA0451
6
5 -Disconnect the coolant liquid inlet hose (7) from the ra-
diator.
RKTA0580
7

WH6 - WH7 30-25
6 -Disconnect the coolant liquid outlet hose (9) from the ra-
diator (8).
RKTA0590
8
9
7 -Disconnect the transmission oil inlet and outlet hoses
(10) from the exchanger. [*2]
a Mark the hoses to avoid mixing them up during in-
stallation.
a Immediately cap the hoses and plug the holes to
prevent contaminants from entering the passages.
RKTA0600
10
8 -Remove the retaining screws and remove the fan guard
(11).
RKTA0531
11
9 -Loosen the screws (12), (13); remove the screws (12)
and disengage the radiator (8) from the brackets (14).
RKTA0610
13
814
12

WH6 - WH730-26
10 -Loosen and remove the lower nuts (15) retaining the
anti-vibration supports (16).
RKTA0551
15
16
11 -Turn the radiator over towards the rear of the machine to
gain access to the nuts (17) retaining the fan (18).
12 -Remove the fan.
13 -Connect the radiator assembly to a hoist and remove it
from the machine.
4 Radiator assembly: 30 kg. approx.
RKTA0562
17
18
Installation
[*1]
a Carry out the coolant liquid filling procedure.
[*2]
a Top up the transmission oil.

WH6 - WH7 30-27
MUFFLER
MUFFLER
Removal
1 -Remove both lengths of the exhaust duct.
(For details, see "EXHAUST PIPE").
2 -Using acoupleof belts, try to support the muffler(1) tem-
porarily.
3 -Disconnect the support (3) from the muffler support (2).
RKTA0620
3
1
2
4 -Loosen and remove the rear screws (4) along with their
respective washers.
5 -Loosen and remove the support’s front screws, remove
their respective washers and remove the muffler (1) to-
gether with its support (2).
RKTA0630
1
2
4
Installation

WH6 - WH730-28
BATTERY – BATTERY TRAY
Removal
• Battery
1 -Lifttheterminalshields (1) and disconnectthecables(2)
and (3).[*1]
k Disconnect the negative (–) cable first, and then
the positive (+) cable.
RKTA0640
13
3
2
++
+++
2 -Loosen the nuts (4) until you are able to remove the
bracket (5) and the battery retaining rods.
RKTA0650
4
4
5
3 -Using the handles provided, remove the battery (6).
RKTA0660
6
• Battery tray
1 -Disconnect the washer pump connectors (7), (8).
a Record the positions for connection.
2 -Mark and then disconnect the feed pipes (9).
3 -Release the strap (10) and remove the tank (11).
RKTA0670
10
11
7
89

WH6 - WH7 30-29
4 -Loosen and remove the screws (12), nuts and washers
retaining the surge tank (13).
5 -Remove the tank and position the tanks aside.
RKTA0401
12
1312
6 -Loosen and remove the screw (14) and the nut retaining
the converter breather tube (15).
RKTA0680
15
14
7 -Loosen and remove the screws (16) together with their
respective washers and remove the battery tray (17).
RKTA0690
16 17
Installation
[*1]
a Connect the positive (+) terminal first, and then the
negative (–) terminal.

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WH6 - WH730-30
CYLINDER HEAD
CYLINDER HEAD
Removal
k Disconnect the cable from the negative (–) battery ter-
minal.
1 -Drain the coolant liquid.
2 -Disconnect the wiring (1) connecting to the coolant liq-
uid temperature sensor (2) and disengage it from the tie-
straps.
3 -Disconnect the wiring (3) from the thermostart (4). RKTA0701
1
2 3
4
4 -Disconnect the oil vapour bleed hose (6) from the valve
(5).
RKTA0442
5
6
5 -Disconnect or remove:
a - the 1st length of the exhaust pipe.
b - the turbocompressor.
c - the coolant liquid surge tank.
d - The fan guard, the fan and the generator belt.
e - Only if equipped: the air conditioner compressor
complete with support.
(For details, see the relevant section for each compo-
nent).
6 -Disconnect the feed hose (7) to the radiator from the cyl-
inder head.
RKTA0580
7

WH6 - WH7 30-31
CYLINDER HEAD
7 -Disconnect the cab heating feed hose (8) from the cyl-
inder head.
8 -Remove the cylinder head and/or replace the cylinder
head gasketbyfollowingtheinstructionsgivenintheen-
gine workshop manuals (code WHBMNEF000).
RKTA0710
8
Installation
• Install the cylinder head by following the instructions giv-
en in the engine workshop manuals (code
WHBMNEF000) and the reverse order for the parts con-
nected to it.
1 -Carry out the coolant liquid filling procedure.

WH6 - WH730-32
INJECTORS
INJECTORS
Removal
1 -Disengage the feed pipes (1) to the injectors from the
wire harness straps and from the retaining clamps.
2 -Perform all the preliminary valve adjusting procedures
described, without removing the valve covers.
RKTA0720
1
1
3 -Disconnect and remove the engine air intake hoses (2),
(3), and the centre support (4).
4 -Remove the injectors in accordance with the instruc-
tions given in the engine workshop manual (code
WHBMNEF000).
RKTA0461
4
2 3
Installation

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Komatsu wh609 1 telescopic handler service repair manual sn 395 f60001 and up