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Komatsu A76001 Shop Manual
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Komatsu A76001 Shop Manual

Komatsu A76001 Shop Manual

Wheel loader
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Manual
WA250
WHEEL LOADER
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
March 2016
-6
WA250-6 A76001
6D107E-1
Copyright 2016 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM000704
and up

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Summary of Contents for Komatsu A76001

  • Page 1 6D107E-1 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. 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 improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 FOREWORD CONTENTS CONTENTS GENERAL ............. 01-1 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD .
  • Page 3 FOREWORD The affected pages are indicated by using the following Mark Indication Action marks. It is requested that necessary actions be taken to ❍ New page to be added these pages according to the table below. ● Page to be replaced Replace Page to be deleted Discard...
  • Page 4 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● ● 10-49 10-82 10-115 10-148 ● ● ● ● 10-50 10-83 10-116 10-149 ● ● ● ● 10-51 10-84 10-117 10-150 ● ● ● ● 10-52 10-85 10-118 10-151 ●...
  • Page 5 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● ● 10-181 10-214 10-247 10-280 ● ● ● 10-182 10-215 10-248 10-281 ● ● ● 10-183 10-216 10-249 10-282 ● ● ● 10-184 10-217 10-250 10-283 ● ● ●...
  • Page 6 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● ● 30-5 30-38 30-71 30-104 ● ● ● ● 30-6 30-39 30-72 30-105 ● ● ● ● 30-7 30-40 30-73 30-106 ● ● ● ● 30-8 30-41 30-74 30-107 ●...
  • Page 7 FOREWORD Mark Page Mark Page Mark Page Mark Page ● 30-137 40-3 40-36 40-69 ● 30-138 40-4 40-37 40-70 ● 30-139 40-5 40-38 40-71 ● 30-140 40-6 40-39 40-72 ● 30-141 40-7 40-40 40-73 ● 30-142 40-8 40-41 40-74 ● 30-143 40-9 40-42...
  • Page 8 FOREWORD Mark Page Mark Page Mark Page Mark Page ● 40-102 40-135 40-168 40-201 40-103 40-136 40-169 40-202 40-104 40-137 40-170 40-203 40-105 40-138 40-171 40-204 40-106 40-139 40-172 40-205 40-107 40-140 40-173 40-206 ● 40-108 40-141 40-174 40-207 40-109 40-142 40-175 40-208...
  • Page 9 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-234 40-267 40-300 40-333 40-235 40-268 40-301 40-334 40-236 40-269 40-302 40-335 40-237 40-270 40-303 40-336 40-238 40-271 40-304 40-337 40-239 40-272 40-305 40-338 40-240 40-273 40-306 40-339 40-241 40-274 40-307 40-340 40-242 40-275...
  • Page 10 FOREWORD Mark Page Mark Page Mark Page Mark Page ● 40-366 40-399 40-432 40-465 ● 40-367 40-400 40-433 40-466 40-368 40-401 40-434 40-467 40-369 40-402 40-435 40-468 40-370 40-403 40-436 40-469 40-371 40-404 40-437 40-470 40-372 40-405 40-438 40-471 40-373 40-406 40-439 40-472...
  • Page 11 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-3 50-36 50-69 50-102 50-4 50-37 50-70 50-103 50-5 50-38 50-71 50-104 50-6 50-39 50-72 50-105 50-7 50-40 50-73 50-106 50-8 50-41 50-74 50-107 50-9 50-42 50-75 50-108 50-10 50-43 50-76 50-109 50-11 50-44...
  • Page 12 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-135 50-168 50-201 50-234 50-136 50-169 50-202 50-235 50-137 50-170 50-203 50-236 50-138 50-171 50-204 50-237 50-139 50-172 50-205 50-238 50-140 50-173 50-206 50-239 50-141 50-174 50-207 50-240 50-142 50-175 50-208 50-241 50-143 50-176...
  • Page 13 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-267 50-300 90-33 ● 50-268 50-301 90-1 90-34 ● 50-269 50-302 90-2 90-35 ● 50-270 50-303 90-3 90-36 ● 50-271 50-304 90-4 90-37 ● 50-272 50-305 90-5 90-38 ● 50-273 50-306 90-6 90-39 ●...
  • Page 14 FOREWORD Mark Page Mark Page Mark Page Mark Page ③ 00-2-12 WA250-6...

  • Page 15: Important Safety Notice

    FOREWORD SAFETY SAFETY Safety Notice Important 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.

  • Page 16: Preparations For Work

    FOREWORD SAFETY Preparations for Work When removing components, be careful not to break or damage the wiring, Damaged wiring may cause Before adding oil or making repairs, park the machine electrical fires. on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
  • Page 17 FOREWORD GENERAL GENERAL This shop manual has been prepared as an aid to improve the Standard Value Table quality of repairs by giving the serviceman an accurate This section explains the standard values for a new machine understanding of the product and by showing him the correct and the judgment criteria for testing, adjusting, and way to perform repairs and make judgments.
  • Page 18 FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL Volumes Revised Edition Mark Shop manuals are issued as a guide to carrying out repairs. When a manual is revised, an edition mark (bcd…) is They are divided as follows: recorded on the bottom, outside corner of the pages.

  • Page 19: Hoisting Instructions

    FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Hoisting Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. ★ If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made.
  • Page 20 FOREWORD HOISTING INSTRUCTIONS Apply wire ropes from the middle portion of the hook. Precautions for Using Overhead Hoist Crane • Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a WARNING! Heavy parts (25 kg (55 lb) or serious accident can result.
  • Page 21 FOREWORD HOISTING INSTRUCTIONS Selecting Wire Ropes 13. If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault protection breaker, Use adequate ropes depending on the weight of parts to check that the devices related to that switch are not in be hoisted.
  • Page 22 FOREWORD AIR CONDITIONER CIRCUITS AIR CONDITIONER CIRCUITS Precautions for Handling Hoses and Tubes Observe these precautions when connecting and disconnecting hoses and tubes in the air conditioner circuit. WARNING! The air conditioner of this machine uses a refrigerant (air conditioner gas: R134a) which has fewer factors to cause the depletion of the ozone layer.
  • Page 23 FOREWORD MAINTENANCE STANDARD TERMS MAINTENANCE STANDARD TERMS The Structure, Function, and Maintenance section explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard Size and Tolerance •...
  • Page 24 FOREWORD MAINTENANCE STANDARD TERMS Repair Limit and Allowable Value or Allowable Dimension • The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the repair limit. • If a part is worn to the repair limit, it must be replaced or repaired. •...
  • Page 25 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT To maintain the performance of the machine over a long period and to prevent failures or other problems before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs.
  • Page 26 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT Disconnections in wiring If the wiring is held and the connectors are pulled apart, components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, the soldering may be damaged, or the wiring may be broken.
  • Page 27 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT B. When removing from clips • Both the connector and clip have stoppers, which are engaged with each other when the connector is installed. • When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing the stoppers.
  • Page 28 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT B. Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. C. Correct any protrusion of the boot and any misalignment of the wiring harness.
  • Page 29 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT E. Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
  • Page 30 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT Handling Controller The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine; be extremely careful when handling the controller. • Do not place objects on top of the controller. •...
  • Page 31 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT Handling Hydraulic Equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
  • Page 32 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
  • Page 33 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT Disconnect connector (1) according to the following procedure. Slide lock (L1) to the right. While pressing lock (L2), pull out connector (1) toward you. Even if lock (L2) is pressed, connector (1) cannot be pulled toward you if part A does not float.
  • Page 34 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT ★ 107 engine (see graphic) ★ If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow. ★...
  • Page 35 FOREWORD HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT ★ Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2) ★ Speed sensor of fuel supply pump: G (SUMITOMO-3) ★ Pull the connector straight up. Turn-housing Type (Round Green Connector) ★ 140 engine ★...

  • Page 36: Precautions For Operations

    FOREWORD PRECAUTIONS FOR OPERATIONS PRECAUTIONS FOR OPERATIONS ★ When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given in this section when carrying out the operation. Precautions when Carrying Out Removal Work •...
  • Page 37 FOREWORD PRECAUTIONS FOR OPERATIONS • If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 11.5 07049-01620 13.5 07049-01822 07049-02025 07049-02228 18.5 07049-02430 07049-02734 22.5 Precautions when Carrying Out Installation Work •...
  • Page 38 FOREWORD PRECAUTIONS FOR OPERATIONS Precautions when Completing the Operation Refilling with coolant, oil, and grease • If the coolant has been drained: • Tighten the drain valve and add coolant to the specified level. • Run the engine to circulate the coolant through the system. •...
  • Page 39 FOREWORD PUSH-PULL COUPLER PUSH-PULL COUPLER WARNING! Before carrying out the following work, release the residual pressure from the hydraulic tank. Loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
  • Page 40 FOREWORD PUSH-PULL COUPLER Type 2 Disconnection Hold the tightening portion and push body (7) in straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) Hold in the condition in Step 1 and turn lever (8) to the right (clockwise).
  • Page 41 FOREWORD PUSH-PULL COUPLER Type 3 Disconnection Hold the tightening portion and push body (9) in straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) Hold in the condition in Step 1 and push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end.

  • Page 42: Coating Materials

    FOREWORD COATING MATERIALS COATING MATERIALS ★ The recommended coating materials prescribed in the shop manuals are listed below. Category Code Part No. Quantity Container Main Applications, Features • Used to prevent rubber gaskets, rubber LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming out •...
  • Page 43 FOREWORD COATING MATERIALS Category Code Part No. Quantity Container Main Applications, Features • Features: Resistance to water, oil • Used as sealant for flange surface, thread. • Also possible to use as sealant for flanges LG-4 790-129-9020 200 g Tube with large clearance.

  • Page 44: Standard Tightening Torque

    FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE Standard Tightening Tables For Bolts and Nuts ★ Unless there are special instructions, tighten metric nuts and bolts to the torque shown in this table. ★ The following table applies to the bolts in Figure A. Thread Diameter Width across Flats Tightening Torque...
  • Page 45 FOREWORD STANDARD TIGHTENING TORQUE ★ This table corresponds to the bolts in Figure B. Thread Diameter Width across Flats Tightening Torque of Bolt N•m lbf in 5.9 – 9.8 0.6 – 1.0 52 – 88 N•m lbf ft 13.7 – 23.5 1.4 –...
  • Page 46 FOREWORD STANDARD TIGHTENING TORQUE For O-Ring Boss Plugs ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque in this table. Thread Diameter Width across Flats Tightening Torque (N•m [kgm] {lbf lb}) Norminal Range Target 5.88 – 8.82 [0.6 – 0.9] {4.33 – 6.50} 7.35 [0.75] {5} 9.8 –...
  • Page 47 FOREWORD STANDARD TIGHTENING TORQUE For Face Seal Joints ★ Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines, etc. to the torque shown in this table. ★ Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted). Tightening Torque N•m [kgm] {lbf ft} Face seal Outer...
  • Page 48 FOREWORD STANDARD TIGHTENING TORQUE For 102, 107, and 114 Engine Series (Taper Screws) ★ Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107, and 114 engine series to the torque in this table. Tightening Torque Material In Cast Iron or Steel In Aluminum...

  • Page 49: Conversion Tables

    FOREWORD CONVERSION TABLES CONVERSION TABLES Method of Using the Conversion Table The Converson 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 •...
  • Page 50 FOREWORD CONVERSION TABLES Millimeters to Inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

Wa250-6