Komatsu wh609 613 713 714 714h 716 1 Shop Manual
Komatsu wh609 613 713 714 714h 716 1 Shop Manual
Komatsu wh609 613 713 714 714h 716 1 Shop Manual
WEBM005700
WH609-1 WH613-1
WH713-1 WH714-1
WH714H-1 WH716-1
TELESCOPIC HANDLER
MODEL SERIAL NUMBER
WH609-1 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
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CONTENTS
CONTENTS
Pagina
10. STRUCTURE AND FUNCTION ...................................................................................... 10-1
REVISED PAGES
The affected pages are indicated by the use of the fol-
lowing marks. It is requested that necessary actions be
taken to these pages according to table below. Mark Indication Action required
k SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual carefully chine on hard, level ground, and block the wheels to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not pos-
on the machine. sible, use blocks to prevent the work equipment from
2. When carrying out any operation, always wear safety falling down. In addition, be sure to lock all the control
shoes and helmet. Do not wear loose work clothes, or levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the ma-
• Always wear safety glasses when hitting parts chine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying machine.
out welding work, always wear welding gloves, apron, Never jump on or off the machine.
glasses, cap and other clothes suited for welding If it is impossible to use the handrails, ladders or steps,
work. use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure be-
fore starting. Always inform your fellow workers be- 11. When removing the oil filler cap, drain plug or hydrau-
fore starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to
work, hang UNDER REPAIR signs on the controls in prevent the oil from spurting out.
the operator’s compartment. Before disconnecting or removing components of the
hydraulic circuit and engine cooling circuit, first re-
5. Keep all tools in good condition and learn the correct
move the pressure completely from the circuit.
way to use them.
6. Decide a place in the repair workshop to keep tools 12. The water and oil in the circuits are not hot when the
and removed parts. Always keep the tools and parts in engine in stopped, so be careful not to get burned.
their correct places. Always keep the work area clean Wait for the oil water to cool before carrying out any
and make sure that there is no dirt or oil on the floor. work on the cooling water circuits.
Smoke only in the areas provided for smoking. Never
13. Before starting work, remove the leads from the bat-
smoke while working.
tery. Always remove the lead from the negative ( – )
terminal first.
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places.
20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent
that they are not twisted. Damaged tubes are dan-
the component from hitting any other part.
gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or
tubes for high pressure circuits. Also, check that
crane.
connecting parts are correctly tightened.
15. When removing covers which are under internal
21. When assembling or installing parts, always use
pressure or under pressure from a spring, always
specified tightening torques.
leave two bolts in position on opposite sides. Slowly
When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to
rotate at high speed, be particulary careful to check
remove.
that they are correctly installed.
16. When removing components, be careful not to
22. When aligning two holes, never insert your fingers or
break or damage the wiring.
hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill-
measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up
any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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 work-
shop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any no-
tice.
Contact your Komatsu Utility distributor for the latest information.
k
work. performing the work.
Safety
FILING METHOD Extra special safety precautions
are necessary when performing
1. See the page number on the bottom of the page. the work because it is under in-
File the pages in correct order. ternal pressure.
2. Following examples show you how to read the page
Special technical precautions or
number.
other precautions for preserving
Example: a Caution
standards are necessary when
10 - 3 performing the work.
3 Tightening
item Parts that require special atten-
tion for the tightening torque dur-
3. Additional pages: additional pages are indicated by torque
ing assembly.
a hyphen (–) and number after the page number.
2
Fle as in the example. Parts to be coated with adhe-
Coat
Example: sives and lubricants etc.
5
10-4 Places where oil, water or fuel
Oil, water must be added, and their quan-
10-4-1 tity.
Added pages
6
10-4-2 Places where oil or water must
10-5 Drain be drained, and quantity to be
drained.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
4
HOISTING INSTRUCTIONS
3
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
a Nm (newton meter): 1 Nm = 0.102 kgm
3
2. TIGHTENING TORQUE FOR NUTS OF FLARED
22 27 8±2 78.5±19.6
33 41 20±5 196.2±49
Sealing surface
1” - 14 30 8.2–9.2 80–90
2” - 12 57 20.4–24.4 200–240
2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking
keys and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
ELECTRIC
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A–B A/B A–G – A–N A/N A–R A/R A–V A/V
Colour Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black Light Blue–Red Light Blue–Green
Code B B–G – B–N B/N B–R B/R – B/V – –
Colour White White–Yellow White–Black White–Red White–Green –
Code C C–B C/B C–L – C–N – – – – –
Colour Orange Orange–White Orange–Blue Orange–Black – –
Code G G–N G/N G–R – G–V – – – – –
Colour Yellow Yellow–Black Yellow–Red Yellow–Green – –
Code H H–L – H–N H/N – – – – – –
Colour Grey Grey–Blue Grey–Black – – –
Code L L–B L/B L–G – – L/N – – – –
Colour Blue Blue–White Blue–Yellow Blue–Black – –
Code M M–B – M–N M/N M–V – – – – –
Colour Brown Brown–White Brown–Black Brown–Green – –
Code N – – – – – – – – – –
Colour Black – – – – –
Code R R–G – R–N R/N R–V – – – – –
Colour Red Red–Yellow Red–Black Red–Green – –
Code S S–G – S–N – – – – – – –
Colour Pink Pink–Yellow Pink–Black – – –
Code V V–B – V–N V/N – – – – – –
Colour Green Green–White Green–Black – – –
Code Z Z–B Z/B Z–N Z/N – – – – – –
Colour Violet Violet–White Violet–Black – – –
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Front wheel
140.0 140.0 140.0 140.0 140.0
Rear wheel
In cold climates
OIL SAE 5W-30
ACEA E5 - E4
OIL
API CH-4 / CI-4 SAE 15W-40
ACEA E5 - E3
Chains
ENGINE OIL SAE 15W-40 as required as required
lubrication
Hydraulic OIL
SAE 10W-30 117 95
system CF - CF2 - CD
Hydraulic
system with
see «4.3.1» 117 95
biodegradable
oil
Front axle:
7.1 7.1
Differential
Final reduction
0.7 0.7
gear (ea.) OIL
Rear axle: UTTO FLUID
7.1 7.1
Differential
Final reduction
0.7 0.7
gear (ea.)
Hydraulic
12.2 10.4
transmission
OIL ATF
Transmission GM DEXRON® II D
(DEXRON® is a reg- 0.25 0.25
reduction gear istered trademark of
General Motors Cor-
poration)
Braking
0.65 0.65
system
✽ ASTM D975 N. 1
NOTE:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds 0.5% change
the engine oil according to the following table:
(2) When starting the engine at temperatures below 0 °C, use engine oil SAE 10W, 20W-20, even if during the day the
temperature increases by 10 °C.
(3) Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a
half.
(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic
circuit of equipment and for reductions.
CONVERSION TABLE
METHOD 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.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.
0 1 2 3 4 5 6 7 8 9
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
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
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
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
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
50 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
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
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