Komatsu WA500-3H Install guide

10-1 WF450-3 / WF450T-3
Shop Manual
VEBM500100
lThis 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.
lWA500-3H mount the SA6D140E-3 engine.
For details of this engine, see the 140-3 Series Engine Shop Manual
© 2001
All Rights Reserved
Printed in Europe 10-01
SERIAL NUMBER WA500H20051 and up
WHEEL LOADER

FOREWORD
00-2 WA500-3H
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 recom-
mended that customers contact their distributor for information on the latest revision.

FOREWORD CONTENTS
WA500-3H 00-3
12
00CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

FOREWORD SAFETY
00-4 WA500-3H
12
00SAFETY
00SAFETY NOTICE
00GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & 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.
•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 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.
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.
00PREPARATIONS FOR WORK
1. 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.
2. 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.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
00IMPORTANT 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 accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.

FOREWORD SAFETY
WA500-3H 00-5
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad-
ders 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.
00PRECAUTIONS DURING WORK
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 components of the oil, water or air circuits, first remove the pressure
completely from the circuit.
2. 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.
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

FOREWORD SAFETY
00-6 WA500-3H
12
4. 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 pre-
vent the component from hitting any other part. Do not
work with any part still raised by the hoist or crane.
5. When removing covers which are under internal pres-
sure 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.
6. When removing components, be careful not to break or
damage the wiring, Damaged wiring may cause electri-
cal fires.
7. 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.
8. As a general rule, do not use gasoline to wash parts. In
particular, use only the minimum of gasoline when
washing electrical parts.
9. Be sure to assemble all parts again in their original
places. Replace any damaged part with new parts.
•When installing hoses and wires, be sure that they will
not be damaged by contact with other parts when the
machine is being operated.
10. 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 pres-
sure circuits. Also check that connecting parts are cor-
rectly installed.
11. 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.
12. When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the
measuring tool is correctly assembled before taking any
measurements.
14. 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.

FOREWORD GENERAL
WA500-3H 00-7
12
00GENERAL
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 fol-
lowing sections. These sections are further divided into each
main group of components.
GENERAL
This section lists the general machine dimensions, per-
formance 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 TROUBLESHOOT-
ING
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.

FOREWORD HOW TO READ THE SHOP MANUAL
00-8 WA500-3H
12
00HOW TO READ THE SHOP MANUAL
00VOLUMES
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
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.
00DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you
start any work.
00FILING 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:
10 - 3
Item number (10. Structure and Function)
Consecutive page number for each item
3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the
example.
Example:
00REVISED EDITION MARK
When a manual is revised, an edition mark (jkl…) is recorded on the bottom outside corner of the pages.
00REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
00SYMBOLS
10-4
10-4-1
Added pages
10-4-2
10-5

FOREWORD HOW TO READ THE SHOP MANUAL
WA500-3H 00-9
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following
symbols.
Symbol 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. Cau-
tion necessary when selecting
hoisting wire or when working
posture is important, etc.
Tightening
torque
Places that require special atten-
tion for tightening torque during
assembly.
Coat Places to be coated with adhe-
sives 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.

FOREWORD HOISTING INSTRUCTIONS
00-10 WA500-3H
12
00HOISTING INSTRUCTIONS
00HOISTING
•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.
00WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
★The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.
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 indi-
cated clearly with the symbol
Wire ropes
(Standard “Z” or “S” twist ropes without galvanizing)
Rope diameter Allowable load
mm kN tons
10 9.8 1.0
11.2 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

FOREWORD HOISTING INSTRUCTIONS
WA500-3H 00-11
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.
3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
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 subject to an
excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°
WARNING! 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 dan-
gerous accident

FOREWORD COATING MATERIALS
00-12 WA500-3H
12
00COATING MATERIALS
★The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
Adhesives
LT-1A 790-129-9030 150 g Tube •Used to prevent rubber gaskets, rubber
cushions and cork plugs from coming out
LT-1B 790-129-9050 20 g
(2 pes.)
Polyethylene
container
•Used in places requiring an immediately
effective, strong adhesive.
•Used for plastics (except polyethylene,
polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
LT-2 09940-00030 50 g Polyethylene
container
•Features: Resistance to heat, chemicals
•Used for anti-loosening and sealant pur-
poses for bolts and plugs.
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
Adhesive:
1 kg
Hardening
agent:
500 g
Can •Used as adhesive or sealant for metal, glass
or plastic.
LT-4 790-129-9040 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 Polyethylene
container
•Quick hardening type adhesive.
•Cure time: within 5 sec. to 3 min.
•Used mainly for adhesion of metals, rub-
bers, plastics and woods.
Aron-
alpha
201
790-129-9130 50 g Polyethylene
container
•Quick hardening type adhesive.
•Quick cure type (max. strength after 30
minutes).
•Used mainly for adhesion of rubbers, plas-
tics and metals.
Loctite
648-50 79A-129-9110 50 cc Polyethylene container
•Features: Resistance to heat, chemicals
•Used at joint portions subject to high tem-
perature.
Gasket seal-
ant
LG-1 790-129-9010 200 g Tube •Used as adhesive or sealant for gaskets and
packing of power train case, etc.
LG-3 790-129-9070 1 kg Can
•Features: Resistance to heat
•Used as sealant for flange surfaces and bolts
at high temperature locations; used to pre-
vent seizure.
•Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.

FOREWORD COATING MATERIALS
WA500-3H 00-13
Gasket seal-
ant
LG-4 790-129-9020 200 g Tube
•Features: Resistance to water, oil
•Used as sealant for flange surface, thread.
•Also possible to use as sealant for flanges
with large clearance.
•Used as sealant for mating surfaces of final
drive case, transmission case.
LG-5 790-129-9080 1 kg Polyethylene
container
•Used as sealant for various threads, pipe
joints, flanges.
•Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
LG-6 09940-00011 250 g Tube
•Features: Silicon based, resistant to heat,
cold.
•Used as sealant for flange surface, thread.
•Used as sealant for oil pan, final drive case,
etc.
LG-7 09920-00150 150 g Tube
•Features: Silicon based, quick hardening
type.
•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
disulphide
lubricant
LM-G 09940-00051 60 g Can •Used as lubricant for sliding parts (to pre-
vent squeaking).
LM-P 09940-00040 200 g Tube
•Used to prevent seizure or scuffing of the
thread when press fitting or shrink fitting.
•Used as lubricant for linkage, bearings, etc.
Grease
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
Various Various •General purpose type
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYG2-
160CNCA
Various Various
•Used for normal temperature, light load
bearing at places in contact with water or
steam.
Molybdenum disulphide lubricant
SYG2-400M 400 g (10 per
case) Belows type •Used for places with heavy load.
Category Code Part No. Quantity Container Main applications, features

FOREWORD STANDARD TIGHTENING TORQUE
00-14 WA500-3H
12
00STANDARD TIGHTENING TORQUE
00STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8

FOREWORD STANDARD TIGHTENING TORQUE
WA500-3H 00-15
12
00TIGHTENING TORQUE OF HOSE NUTS
Use these torques for hose nuts.
00TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
00TIGHTENING TORQUE FOR FLARED NUTS
Use these torques for flared part of nut.
Nominal No. Thread diameter Width across flat Tightening torque
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5 ± 2
04 22 27 78.5 ± 19.6 8 ± 2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ±4.9 2.5 ±0.5
18 24 49 ±19.6 5 ±2
22 27 78.5 ±19.6 8 ±2
24 32 137.3 ±29.4 14 ±3
30 36 176.5 ±29.4 18 ±3
33 41 196.1 ±49 20 ±5
36 46 245.2 ±49 25 ±5
42 55 294.2 ±49 30 ±5

FOREWORD ELECTRIC WIRE CODE
00-16 WA500-3H
12
00ELECTRIC 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.
00CLASSIFICATION BY THICKNESS
00CLASSIFICATION BY COLOR AND CODE
Nominal num-
ber
Copper wire Cable O.D.
(mm)
Current rat-
ing (A) Applicable circuit
Number of
strands
Dia. Of strand
(mm)
Cross section
(mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 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 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Priority
Circuits
Classi-
fication
Charging Ground Starting Lighting Instrument Signal Other
1
Primary
Code W B B R Y G L
Color White Black Black Red Yellow Green Blue
2
Auxiliary
CodeWR — BWRW YRGWLW
Color White &
Red —Black & White
Red &
White
Yellow &
Red
Green &
White
Blue &
White
3
Code WB — BY RB YB GR LR
Color White &
Black —Black & Yel- low Red & Black Yellow & Black
Green &
Red Blue & Red
4
Code WL — BR RY YG GY LY
Color White &
Blue — Black & Red Red & Yel- low
Yellow &
Green
Green &
Yellow
Blue & Yel-
low
5
Code WG — — RG YL GB LB
Color White &
Green ——
Red &
Green
Yellow &
Blue
Green &
Black
Blue &
Black
6
Code — — — RL YW GL —
Color — — — Red & Blue Yellow &
White
Green &
Blue —

FOREWORD CONVERSION TABLES
WA500-3H 00-17
12
00CONVERSION TABLES
00METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
•Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as j, then draw a horizontal line from j.
B. Locate the number 5 in the row across the top, take this as k, then draw a perpendicular line down from k.
C. Take the point where the two lines cross as l. This point lgives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
k
Millimeters to inches 1 mm = 0.03937 in
0123456789
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
l
j50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

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