KOMATSU WH613-1 Telescopic HandLERS Service Manual
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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
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k SAFETY
k 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 Utility and describe in this manual are both ef-
fective and safe methods of operation. Some of these operations require the use of tools specially designed
by Komatsu Utility for the purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be carefully followed. If any danger arises or may possibly arise,
first consider safety, and take necessary steps to face.
GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual carefully
BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all
the precautions written on the decals which are suck
on 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 be-
fore starting. Always inform your fellow workers be-
fore 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.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chine on hard, level ground, and block the wheels to
prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or any
other work equipment to the ground. If this is not pos-
sible, use blocks to prevent the work equipment from
falling down. In addition, be sure to lock all the control
levers and hang warning sign on them.
9. When disassembling or assembling, support the ma-
chine with blocks, jacks or stands before starting
work.
10. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
handrails, ladders 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.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydrau-
lic pressure measuring plugs, loosen them slowly to
prevent the oil from spurting out.
Before disconnecting or removing components of the
hydraulic circuit and engine cooling circuit, first re-
move the pressure completely from the circuit.
12. The water and oil in the circuits are not hot when the
engine in stopped, so be careful not to get burned.
Wait for the oil water to cool before carrying out any
work on the cooling water circuits.
13. Before starting work, remove the leads from the bat-
tery. Always remove the lead from the negative ( – )
terminal first.
k SAFETY
WH6 - WH7
00-6
k SAFETY
14. 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 ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist or
crane.
15. When removing covers which are under internal
pressure 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.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spill-
ing 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 minimum of gasoline when
washing electrical parts.
19. Be sure to assemble all parts again in their original
places. Replace any damage parts 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.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to check
that they are correctly installed.
22. When aligning two holes, never insert your fingers or
hand.
23. When measuring hydraulic pressure, check that the
measuring tool is correctly assembled before taking
any measurement.
24. Take sure when removing or installing wheels.
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FOREWORD
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.
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 sections 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.
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.
WH6 - WH7
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HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES
Shop manual are issued as a guide to carry out repairs.
These various volumes are designed to avoid duplicat-
ing the same information.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to Komatsu Utility distributors.
Get the most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show you how to read the page
number.
Example:
3. Additional pages: additional pages are indicated by
a hyphen (–) and number after the page number.
Fle as in the example.
Example:
REVISED EDITION MARK
When a manual is revised, an edition mark is recorded
on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
SYMBOLS
In order to make the shop manual greatly chelpful, im-
portant points about safety and quality are marked with
the following symbols.
10 3
Item number (10. Structure and
Function)
Consecutive page number for each
item
-
10-4
10-4-1
10-4-2
10-5
Added pages
Symbol Item Remarks
k Safety
Special safety precautions
are necessary when
performing the work.
Extra special safety precautions
are necessary when performing
the work because it is under in-
ternal pressure.
a Caution
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
4 Weight
Weight of parts or systems.
Caution necessary when select-
ing hoisting wire, or when work-
ing posture is important, etc.
3
Tightening
torque
Parts that require special atten-
tion for the tightening torque dur-
ing assembly.
2 Coat
Parts to be coated with adhe-
sives and lubricants etc.
5 Oil, water
Places where oil, water or fuel
must be added, and their quan-
tity.
6 Drain
Places where oil or water must
be drained, and quantity to be
drained.
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Lifetime Access
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Print one or all pages of your manual
$33.99
$44.99
The KOMATSU WH613-1 TELESCOPIC HANDLERS SN 395F60003 and up service manual is an essential resource for professionals and DIY enthusiasts alike. It provides accurate technical information for repairs and maintenance, covering various aspects such as structure and function, testing and adjusting, disassembly and assembly, and more.
This comprehensive manual allows users to print specific pages or the entire document, with detailed substeps, notes, cautions, and warnings throughout each chapter. It includes numbered instructions, bold figure numbers, detailed illustrations, and enlarged insets to facilitate easy identification and examination of parts. The numbered table of contents makes it convenient to locate information quickly.
The manual is available in .PDF format, compatible with all versions of Windows and Mac. It can be saved to the hard drive, burned to CD-ROM, and printed as needed, eliminating the need for shipping or waiting for physical copies to arrive.
Key topics covered in the manual include structure and function, hydraulic system, electrical system, mechatronics system, troubleshooting, maintenance standards, disassembly and assembly, and component mounting torque. It also provides detailed information on safety hints, specifications, and operational performance tests.
Whether for understanding the engine system, electric system, hydraulic system, undercarriage, structure, or work equipment, the KOMATSU WH613-1 TELESCOPIC HANDLERS SN 395F60003 and up service manual is an invaluable guide for maintaining and repairing this equipment.
