Komatsu Wheel Loaders Wa350 1 Shop Manual

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KOMATSU

WA3504
MACHINE MODEL SERIAL No.

WA350- 1 10001 and up

l 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.

l WA350-1 mount the S6Dll O-l engine.

For details of the engine, see the 110 Series Engine Shop Manual.

oo-1
05-90(03)03561
a
This is the cut pages sample. Download all 781 page(s) at: ManualPlace.com
 CONTENTS

No. of page
10 ENGINE
11 STRUCTURE AND FUNCTION .. . . .. . . . ... .. . . ........ ... 1 l-l
12 TESTING AND ADJUSTING ................................................. 12-1
13 DISASSEMBLY AND ASSEMBLY.. . .. . . . ..... . . .. . . . 13-1

20 POWER TRAIN
21 STRUCTURE AND FUNCTION ............................................... 21-1
22 TESTING AND ADJUSTING ................................................. 22-l
23 DISASSEMBLY AND ASSEMBLY ............................................. 23-l
24 MAINTENANCE STANDARD ................................................. 24-l

40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION ............................................... 41-1
42 TESTING AND ADJUSTING ................................................. 42-l
43 DISASSEMBLY AND ASSEMBLY ............................................. 43-l
44 MAINTENANCE STANDARD ................................................. 44-l

50 BRAKE AND AIR SYSTEM

51 STRUCTURE AND FUNCTION ............................................... 51-1
52 TESTING AND ADJUSTING ................................................. 52-l
53 DISASSEMBLY AND ASSEMBLY ............................................. 53-l
54 MAINTENANCE STANDARD ................................................. 54-l

60 WORK EQUIPMENT SYSTEM

61 STRUCTURE AND FUNCTION ............................................... 61-1
62 TESTING AND ADJUSTING ................................................. 62-l
63 DISASSEMBLY AND ASSEMBLY ............................................. 63-l
64 MAINTENANCE STANDARD ................................................. 64-l

80 ELECTRIC AND ELECTRONIC SYSTEM

81 STRUCTURE AND FUNCTION ............................................... 81-1
82 TESTING AND ADJUSTING ................................................. 82-l
83 DISASSEMBLY AND ASSEMBLY ............................................. 83-l

90 OTHERS
91 STRUCTURE AND FUNCTION ............................................... 91-1
93 DISASSEMBLY AND ASSEMBLY ............................................. 93-l
97 GEAR PUMP ................................................................ 97-l

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00-2 -4 WA350-1
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 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.

*& are
To prevent injury to workers, the symbols A and
4
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 6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for
1. Before carrying out any greasing or repairs,
smoking. Never smoke while working.
read all the precautions given on the
decals which are fixed to the machine.

2.When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when
8. Before starting work, lower blade, ripper,
grinding parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, equipment from falling. In addition, be sure
always wear welding gloves, apron, glasses, to lock all the control levers and hang
cap and other clothes suited for welding warning signs on them.

work. 9. When disassembling or assembling, sup-

port the machine with blocks, jacks or
4.When carrying out any operation with two
stands before starting work.
or more workers, always agree on the op-
erating procedure before starting. Always 10. Remove all mud and oil from the steps or
inform your fellow workers before starting other places used to get on and off the
any step of the operation. Before starting machine. Always use the handrails, ladders
or steps when getting on or off the
work, hang UNDER REPAIR signs on the
machine. Never jump on or off the machine.
controls in the operator’s compartment.
If it is impossible to use the handrails,
5. Keep all tools in good condition and learn ladders or steps, use a stand to provide safe
the correct way to use them. footing.

00-3
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, l When installing hoses and wires, be
loosen them slowly to prevent the oil from sure that they will not be damaged by
spurting out. contact with other parts when the ma-
Before disconnecting or removing compo- chine is being operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
circuit. sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot
ful when installing tubes for high pressure
when the engine is stopped, so be careful
circuits. Also, check that connecting parts
not to get burned.
are correctly installed.
Wait for the oil and water to cool before car-
rying out any work on the oil or water 21. When assembling or installing parts, always
circuits. use the specified tightening torques. When

13. Before starting work, remove the leads from installing protective parts such as guards, or
the battery. Always remove the lead from parts which vibrate violently or rotate at
the negative (-1 terminal first. high speed, be particularly careful to check
that they are installed correctly.
14. When raising heavy components, use a
hoist or crane. 22. When aligning two holes, never insert your
Check that the wire rope, chains and hooks fingers or hand. Be careful not to get your
are free from damage. fingers caught in a hole.
Always use lifting equipment which has
ample capacity. 23. When measuring hydraulic pressure, check
Install the lifting equipment at the correct that the measuring tool is correctly assem-
places. Use a hoist or crane and operate bled before taking any measurements.
slowly to prevent the component from hit-
24. Take care when removing or installing the
ting any other part. Do not work with any
tracks of track-type machines.
part still raised by the hoist or crane.
When removing the track, the track sepa-
15. When removing covers which are under in- rates suddenly, so never let anyone stand at
ternal pressure or under pressure from a
either end of the track.
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.

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 REVISED EDITION MARK (@)a@ -.-- )

Shop manuals are issued as a guide to carry- When a manual is revised, an edition mark is
ing out repairs. They are divided as follows: recorded on the bottom outside corner of the
pages.
Chassis volume: Issued for every machine
model
Engine volume: Issued for each engine series
Each issued as
Electrical volume REVISIONS
one volume to
Attachments volume
cover all models Revised pages are shown at the LIST OF
REVISED PAGES on the between the title page
and SAFETY page.
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. SYMBOLS

So that the shop manual can be of ample

DISTRIBUTION AND UPDATING
practical use, important places for safety and
Any additions, amendments or other quality are marked with the following symbols.
changes will be sent to KOMATSU distributers.
Get the most up-to-date information before
you start any work.
Symbol Item Remarks
FILING METHOD
Special safety precautions are
1. See the page number on the bottom of the A necessary when performing
work.
the

page. File the pages in correct order. Safety

2. Following examples shows how to read the Extra special safety precautions
page number. *& are necessary when performing
Example 1 (Chassis volume): * the work because it is under
internal pressure.
IO-3
Special technical precautions or
other precautions for
Item number (IO. Structure * Caution preserving standards are
and Function) necessary when performing the
% Consecutive page number for work.
each item.
Weight of parts or systems.
Example 2 (Engine volume): Caution necessary when
Weight selecting hoisting wire, or when
12-410 working posture is important,
etc.
Unit number (I. Engine)
Item number (2. Testing and Places that require special
Tighten-
Adjusting) attention for the tightening
ig torque ?
torque during assembly.
Group No. (4. Fuel system)
F Consecutive page No. (Page
Places to be coated with
10 of Group 4) Coat
adhesives and lubricants etc.

3. Additional pages: Additional pages are in- Places where oil, water or fuel
dicated by a hyphen (-1 and number after the Xl, water must be added, and the
page number. File as in the example. capacity.
Example:
Places where oil or water must
1 o-4 12-203 Drain be drained, and quantity to be
drained.

1 o-5 12-204

00-6
HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

Slinging near the edge of the hook may

Heavy parts (25 kg or more) must be
cause the rope to slip off the hook during
lifted with a hoist etc. In the Disassembly
hoisting, and a serious accident can result.
Hooks have maximum strength at the
middle portion.

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
100% 88% 79% 71% 41%
the part to the relative parts.
FSO064
. Check for existence of another part
causing interference with the part to be 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
rem-oved.
symmetrically wound on to the load.

2. Wire ropes
A Slinging
turning
with one rope may cause
of the load during hoisting,
untwisting of the rope, or slipping of
I) Use adequate ropes depending on the
the rope from its original winding
weight of parts to be hoisted, referring to
position on the load, which can result
the table below:
in a dangerous accident.

4) Do not sling a heavy load with ropes

Wire ropes
forming a wide hanging angle from the
(Standard “Z” or “S” twist ropes
hook.
without galvanizing)
When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter (mm) Allowable load (tons)
will increase with the hanging angles. The
table below shows the variation of
10 1 .o
allowable load (kg) when hoisting is made
11.2 1.4 with two ropes, each of which is allowed
12.5 1.6 to sling up to 1000 kg vertically, at various
hanging angles.
14 2.2
When two ropes sling a load vertically, up
16 2.8 to 2000 kg of total weight can be
ia 3.6 suspended. This weight becomes 1000 kg
when two ropes make a 120” hanging
20 4.4
angle. On the other hand, two ropes are
22.4 5.6 subjected to an excessive force as large as
30 10.0 4000 kg if they sling a 2000 kg load at a
lifting angle of 150”.
40 I a.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

30” 60” go* 120’ 150”
of the hook.
Lifting angle : 01
FSO065

00-7
STANDARD TIGHTENING TORQUE

m 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)
I km I Nm

.. 10 1.35kO.15 13.2* 1.4

6
8 13 3.2kO.3 31.4k2.9
10 17 6.7 f 0.7 65.7k6.8
12 19 11.5*1.0 112t9.8
14 - 22 18.0t2.0 177*19

16 24 28.5*3 279&29
18 27 3924 383?39
20 30 56*6 549*58
22 32 76+8 745278
24 36 94.5* 10 927*98

27 41 135+15 1320+ 140

30 46 175220 1720-r 190
33 50 225&25 221 Ok240
36 55 28Ok30 27502290
39 60 335t35 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.

Sr Nm (newton meter): 1 Nm + 0.1 kgm

2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread: gtl,eter Width Tightening torque

across flats
(mm) (mm) kgm Nm

10 14 6.7kO.7 65.7 k6.8

12 17 II.521 112t9.8
16 22 28.5t3 279t29

00-8
STANDARD TIGHTENING TORQUE

Sealing surface

3.TlGHTENlNG TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter
of nut part
Width across flats
of nut part
r Tightening torque

(mm) (mm) km Nm

14 19 2.5kO.5 24.5 k4.9

18. 24 522 49* 19.6

22 27 822 78.5 f 19.6

24 32 1423 137.3k29.4

30 36 1823 176.5229.4

33 41 20*5 196.1 &49

36 46 2525 245.2+49

42 55 30&5 294.2*49

COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.

Nomenclature Komatsu code Applications

LT-1 A Used to apply rubber pads, rubber gaskets, and cork plugs.

Used to apply resin, rubber, metallic and

LT-18
Adhesives non-metallic parts when a fast, strong seal is needed.

LT-2” Preventing bolts, nuts and plugs from loosening and leaking oil.

Provides an airtight, electrically insulating seal.

LT-3
Used for aluminum surfaces.

LG-1 Used with gaskets and packings to increase sealing effect.

Heat-resistant gasket for precombustion chambers

LG-3
and exhaust piping.
Gasket sealant
Used by itself on mounting surfaces on the final drive and trans-
LG-4
mission cases. (Thickness after tightening: 0.07 - 0.08 mm)
Used by itself to seal grease fittings, tapered screw
LG-5 fittings and tapered screw fittings in hydraulic circuits
of less than 50 mm in diameter.
Antif riction com-
pound (Lubricant Applied to bearings and taper shafts to facilitate press-fitting and to
LM-P
including molybde- prevent sticking, burning or rusting.
num disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust
G2-LI
(Lithium grease) prevention and facilitation of assembling work.

Vaseline - Used for protecting battery electrode terminals from corrosion.

lLT-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

Copper wire
Nominal _ Cable O.D.
Applicable circuit
number Number Dia. TF;ands Cross section (mm)
str_ands (mm2)

0.85 1 11 1 0.32 1 0.88 1 2.4 1 12 1 Starting, lighting, signal etc.

2 1 26 1 0.32 / 2.09 I 3.1 I 20 1 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 1 1.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits

ity
Class+ ChTng / GrTd Signal Other
fication
\
G I L
1
White Black

Code WR -
2
Color White & Red -

Code WB
3
&xi_ “‘Or White & Black -
liary
WL
t Code
4
Color White&Blue -

Code
5
t- Color
/ Code (GLI 1 -
6
Color (Green & Blue) 1 -

00-l 0
GENERAL WEIGHT TABLE

WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.

(Unit: kg)

11118
‘3Yl7 and up

Engine assembly 700 700

Radiator assembly 105 105

Torque converter assembly 160 160

Lift cylinder (I piece)

Dump cylinder 185 185

Engine hood 134 134

Rear drive shaft 12 12 Front frame 1,250 1,308

I I

Front axle assembly ) 1,129 1 1,129 Rear frame 1,040 1,021

I

Rear axle assembly 1,109 1,109 Bucket link 52 52

Front differential assembly 191 191 Tilt lever 248 248

)
Rear differential assembly 176 176

P~;t&rr~carrier assembly 68 1 68
II !

Planetary hub assembly 73 ( 73

(I piece) I
Axle pivot Front/Rear 1 61183 ( 61183 Fuel tank 204 204

Wheel (1 piece) 1 100 1 100 Battery (1 piece) 44 44

Tire (I piece) 210 210 Operator’s seat 37 37

Steering valve 32 32 Floor plate 75 75

Steering cylinder (1 piece) 27 27 CAB 310 310

Brake (1 piece) 111 111

l : with teeth.
l * : with bolt on cutting edge.

WA350-1 00-l 1
0
GENERAL TABLE OF OIL AND COOLANT QUANTITIES

TABLE 0 : OIL AND COOLANT QUANTITIES

RESERVOIR

Engine oil pan

Brake

Transmission case

Hydraulic system

Axle See NOTE (4) each 45 each 45

(Front and rear)

oiese, fue, LASTPAD975 No. 1

Fuel tank

Cooling system Water Add antifreeze 52 -

NOTE:
(1) When fuel sulphur content is less than 0.5%. (2) When starting the engine in an atmospherric tem-
change oil in the oil pan every periodic mainte- perature of lower then 0°C. be sure to use engine
nance hours described in this manual. oil of SAEIOW, SAEIOW-30 and SAEI 5W-40,
Change oil according to the following table if fuel even though an atmospheric temperature goes up
sulphur content is above 0.5%. 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
Above 1.0% l/4 of regular interval
I TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
* It is possible to substitute engine oil CLASS-CD
SAEBO for axle oil.

ASTM: American Society of Testing and Material

SAE: Society of Automotive 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.

00-12 WA350- 1
0
 ENGINE
11 STRUCTURE AND FUNCTION

Engine mount .............................. 11-2

Radiator .................................. 11-3
Fueltankandpiping ........................ 11-4
Engine control ............................. 1 1-5

WA350-1 11-1
STRUCTURE AND FUNCTION ENGINE MOUNT

ENGINE MOUNT

423FOO5

. The engine, torque converter, transmission, and

transfer are each joined together.
. There are rubber mounts at the engine end and
transfer end.

1. Transmission mount
2. Engine mount
View 2

11-2 WA350-1
STRUCTURE AND FUNCTION RADIATOR

RADIATOR

Section X-X

423FOO6

I. Radiator Specifications
2. Coolant level sensor Core type: G6 type
3. Fan guard Total heat dissipating area: 52.57 m2
4. Hydraulic oil cooler Cross-sectional area of water tubes: 138 cm2
5. Torque converter oil cooler
A. Coolant inlet port
6. Coolant outlet port

WA350- 1 11-3
Komatsu Wheel Loaders Wa350 1 Shop Manual
Full download: http://manualplace.com/download/komatsu-wheel-loaders-wa350-1-shop-manual/

STRUCTURE AND FUNCTION FUEL TANK AND PIPING

FUEL TANK AND PIPING

The fuel level sensor is installed in the fuel tank.

__

F4230001

1. Connector
2. Fuel level sensor
3. Injection pump
4. Drain cock
5. Fuel filler port

11-4 WA350- 1

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