![REMOVAL AND INSTALLATION
WH6 - WH7 30-15
ENGINE HOOD
ENGINE HOOD
Removal
1 -Lift the engine hood (1).
RKTA0330
1
2 -While supporting the engine hood, loosen and remove
the screws (2) retaining the hinges (3).
RKTA0340
3
2
3 -Remove the cotter pin (4), the backing washer, and dis-
connect the gas damper (5) from its support (6).
RKTA0350
4
5
6
4 -Lower the hood and place an anti-slip block (A) between
lower edge of hood and body; then, strap the hood and
connect it a hoist.
5 -Remove the hood (1). [*1]
RKTA0360
A](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-3-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7
30-16
ENGINE HOOD
Installation
ā¢ To install, reverse the removal procedure.
[*1]
1 -Adjust thepositionof thehood, ensuring thatthe lock as-
sembly (7) is centred in relation to the retaining hook (8).
RKTA0370
7
8
2 -Adjust the hinges vertically (3) to allow the closure seal-
ing strip (9) to evenly rest along the length of the hood.
RKTA0380
3
9
3 -Adjust the hinges (3) horizontally until full contact be-
tweenthesealingstrip(10)andtheengine-transmission
mount (11) is achieved.
RKTA0390
3
10
11](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-4-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7
30-20
EXHAUST PIPE
EXHAUST PIPE
Removal
ā¢ 1st Length
1 -Loosen and remove the screws (1) securing the pipe (2)
to the turbocompressor (3) (models with turbo engine),
or to the exhaust manifold (models with aspirated en-
gine).
a Models with aspirated engine:
replace the gasket between exhaust pipe and man-
ifold at each disassembly.
RKTA0471
2
1
3
2 -Loosenandremovethescrews(4)togetherwiththeirre-
spective washers, and remove the pipe (2).
a Replace the gasket between exhaust pipe and muf-
fler at each disassembly.
3 -Remove the pipe (1).
RKTA0490
4
2
4
ā¢ 2nd
Length
1 -Loosen and remove the screws (5) and remove the tail
pipe (6). [*1]
RKTA0500
6
5
2 -Loosen and remove the screws (7) securing the 2nd
length of the pipe (8) to the muffler (9).
a Replace the gasket between exhaust pipe and muf-
fler at each disassembly.
RKTA0510
7
8
9](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-8-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7 30-21
EXHAUST PIPE
3 -Loosen the screw (10) remove the retaining screw (11),
and remove the clamp (12).
4 -Remove the pipe (8).
RKTA0520
8
10
11
12
Installation
ā¢ To install, reverse the removal procedure.
[*1]
a Before locking the tail pipe (6), adjust it until it is cen-
tred in relation to the 2nd length of the exhaust.](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-9-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7 30-23
GENERATOR ā FAN BELT
6 -Remove the worn belt (10) and replace it by performing
the relevant procedures described in the engine work-
shop manual. [*1]
RKTA0561
10
Installation
ā¢ To install, reverse the removal procedure.
[*1]
a Tension the belt by performing the belt tensioning
procedure described in the engine workshop man-
ual (code WHBMNEF000).](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-11-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7
30-24
RADIATOR-EXCHANGER ASSEMBLY
RADIATOR-EXCHANGER ASSEMBLY
Removal
1 -Unscrew the cap (1) and drain the coolant liquid. [*1]
6 Coolant liquid: 20 l approx.
RKTA0541
1
2 -Loosen and remove the screws (2) retaining the clamps
(3).
3 -Disconnect the hose (5) connecting to the expansion
tank from the cap (4).
RKTA0570
3
4
5
2
3
4 -Disconnect and remove the engine air intake hose (6).
RKTA0451
6
5 -Disconnect the coolant liquid inlet hose (7) from the ra-
diator.
RKTA0580
7](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-12-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7 30-25
RADIATOR-EXCHANGER ASSEMBLY
6 -Disconnect the coolant liquid outlet hose (9) from the ra-
diator (8).
RKTA0590
8
9
7 -Disconnect the transmission oil inlet and outlet hoses
(10) from the exchanger. [*2]
a Mark the hoses to avoid mixing them up during in-
stallation.
a Immediately cap the hoses and plug the holes to
prevent contaminants from entering the passages.
RKTA0600
10
8 -Remove the retaining screws and remove the fan guard
(11).
RKTA0531
11
9 -Loosen the screws (12), (13); remove the screws (12)
and disengage the radiator (8) from the brackets (14).
RKTA0610
13
8
14
12](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-13-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7
30-26
RADIATOR-EXCHANGER ASSEMBLY
10 -Loosen and remove the lower nuts (15) retaining the
anti-vibration supports (16).
RKTA0551
15
16
11 -Turn the radiator over towards the rear of the machine to
gain access to the nuts (17) retaining the fan (18).
12 -Remove the fan.
13 -Connect the radiator assembly to a hoist and remove it
from the machine.
4 Radiator assembly: 30 kg. approx.
RKTA0562
17
18
Installation
ā¢ To install, reverse the removal procedure.
[*1]
a Carry out the coolant liquid filling procedure.
5 Coolant liquid: 20 l approx.
[*2]
a Top up the transmission oil.](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-14-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7
30-28
BATTERY ā BATTERY TRAY
BATTERY ā BATTERY TRAY
Removal
ā¢ Battery
1 -Lifttheterminalshields (1) and disconnectthecables(2)
and (3).[*1]
k Disconnect the negative (ā) cable first, and then
the positive (+) cable.
RKTA0640
1
3
3
2
+
+
+
+
+
2 -Loosen the nuts (4) until you are able to remove the
bracket (5) and the battery retaining rods.
RKTA0650
4
4
5
3 -Using the handles provided, remove the battery (6).
RKTA0660
6
ā¢ Battery tray
1 -Disconnect the washer pump connectors (7), (8).
a Record the positions for connection.
2 -Mark and then disconnect the feed pipes (9).
3 -Release the strap (10) and remove the tank (11).
RKTA0670
10
11
7
8
9](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-16-320.jpg)
![REMOVAL AND INSTALLATION
WH6 - WH7 30-29
BATTERY ā BATTERY TRAY
4 -Loosen and remove the screws (12), nuts and washers
retaining the surge tank (13).
5 -Remove the tank and position the tanks aside.
RKTA0401
12
13
12
6 -Loosen and remove the screw (14) and the nut retaining
the converter breather tube (15).
RKTA0680
15
14
7 -Loosen and remove the screws (16) together with their
respective washers and remove the battery tray (17).
RKTA0690
16 17
Installation
ā¢ To install, reverse the removal procedure.
[*1]
a Connect the positive (+) terminal first, and then the
negative (ā) terminal.](https://image.slidesharecdn.com/komatsuwh609-1telescopichandlerservicerepairmanualsn395f60001andup-210604081039/85/Komatsu-wh609-1-telescopic-handler-service-repair-manual-sn-395-f60001-and-up-17-320.jpg)
Komatsu wh609 1 telescopic handler service repair manual sn 395 f60001 and up
- 1. WEBM005700 WH613-1 WH609-1 WH713-1 WH714-1 WH714H-1 WH716-1 TELESCOPIC HANDLER MODEL WH609-1 SERIAL NUMBER 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
- 2. WH6 - WH7 00-1 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
- 3. REMOVAL AND INSTALLATION WH6 - WH7 30-15 ENGINE HOOD ENGINE HOOD Removal 1 -Lift the engine hood (1). RKTA0330 1 2 -While supporting the engine hood, loosen and remove the screws (2) retaining the hinges (3). RKTA0340 3 2 3 -Remove the cotter pin (4), the backing washer, and dis- connect the gas damper (5) from its support (6). RKTA0350 4 5 6 4 -Lower the hood and place an anti-slip block (A) between lower edge of hood and body; then, strap the hood and connect it a hoist. 5 -Remove the hood (1). [*1] RKTA0360 A
- 4. REMOVAL AND INSTALLATION WH6 - WH7 30-16 ENGINE HOOD Installation ā¢ To install, reverse the removal procedure. [*1] 1 -Adjust thepositionof thehood, ensuring thatthe lock as- sembly (7) is centred in relation to the retaining hook (8). RKTA0370 7 8 2 -Adjust the hinges vertically (3) to allow the closure seal- ing strip (9) to evenly rest along the length of the hood. RKTA0380 3 9 3 -Adjust the hinges (3) horizontally until full contact be- tweenthesealingstrip(10)andtheengine-transmission mount (11) is achieved. RKTA0390 3 10 11
- 5. REMOVAL AND INSTALLATION WH6 - WH7 30-17 AIR FILTER AIR FILTER Removal 1 -Unscrewand remove thecap(1) fromthe surge tank (2). 2 -Loosen and remove the screws (3), remove the surge tank (2), and position the tank aside. RKTA0400 1 3 2 3 3 -Loosen the clamps (4), (5) and disconnect the outside airinlethose(7)andengineintakehose(8)fromthefilter (6). RKTA0410 4 5 6 7 8 4 -Disconnect the air cleaner clogging sensor connector (9). RKTA0420 9 5 -Loosen and remove the screws (10) together with wash- ers and nuts and remove the filter (6). Installation ā¢ To install, reverse the removal procedure. RKTA0430 10 6
- 6. REMOVAL AND INSTALLATION WH6 - WH7 30-18 TURBOCOMPRESSOR (only if equipped) TURBOCOMPRESSOR (only if equipped) Removal 1 -Remove the engine hood. (For details, see "ENGINE HOOD"). RKTA0361 2 -Disconnect the outside air inlet hose (2) from the air cleaner (1). RKTA0411 1 2 3 -Disconnect the hose (4) from the oil vapour bleed valve (3) and remove the air cleaner-to-turbocompressor hose (5). RKTA0440 3 4 5 4 -Loosen the clamps (6) and remove the hose (7). RKTA0450 6 7 6
- 7. REMOVAL AND INSTALLATION WH6 - WH7 30-19 TURBOCOMPRESSOR (only if equipped) 5 -Loosen and remove the three screws (8) and remove the support (9). RKTA0460 9 8 6 -Loosen and remove the screws (10) retaining the ex- haust pipe (11). RKTA0470 10 11 7 -Disconnect the exhaust pipe (11) and recover the gas- ket (12). RKTA0480 11 12 8 -Remove the turbocompressor following the instructions given in the engine workshop manual (code WHBMNEF000). Installation ā¢ To install, reverse the removal procedure.
- 8. REMOVAL AND INSTALLATION WH6 - WH7 30-20 EXHAUST PIPE EXHAUST PIPE Removal ā¢ 1st Length 1 -Loosen and remove the screws (1) securing the pipe (2) to the turbocompressor (3) (models with turbo engine), or to the exhaust manifold (models with aspirated en- gine). a Models with aspirated engine: replace the gasket between exhaust pipe and man- ifold at each disassembly. RKTA0471 2 1 3 2 -Loosenandremovethescrews(4)togetherwiththeirre- spective washers, and remove the pipe (2). a Replace the gasket between exhaust pipe and muf- fler at each disassembly. 3 -Remove the pipe (1). RKTA0490 4 2 4 ā¢ 2nd Length 1 -Loosen and remove the screws (5) and remove the tail pipe (6). [*1] RKTA0500 6 5 2 -Loosen and remove the screws (7) securing the 2nd length of the pipe (8) to the muffler (9). a Replace the gasket between exhaust pipe and muf- fler at each disassembly. RKTA0510 7 8 9
- 9. REMOVAL AND INSTALLATION WH6 - WH7 30-21 EXHAUST PIPE 3 -Loosen the screw (10) remove the retaining screw (11), and remove the clamp (12). 4 -Remove the pipe (8). RKTA0520 8 10 11 12 Installation ā¢ To install, reverse the removal procedure. [*1] a Before locking the tail pipe (6), adjust it until it is cen- tred in relation to the 2nd length of the exhaust.
- 10. REMOVAL AND INSTALLATION WH6 - WH7 30-22 GENERATOR ā FAN BELT GENERATOR ā FAN BELT Removal 1 -Loosen and remove the retaining screws and remove the fan guard (1). RKTA0530 1 2 -Loosen the screws (2) and (3); remove the screws (2) and disengage the radiator (4) from the brackets (5). RKTA0540 5 3 4 2 3 -Loosen the lower nuts (6) retaining the anti-vibration supports (7). RKTA0550 6 7 4 -Turn the radiator over and towards the rear of the ma- chine to gain access to the fan retaining nuts (8) and washers. 5 -Remove the fan. RKTA0560 8 9
- 11. REMOVAL AND INSTALLATION WH6 - WH7 30-23 GENERATOR ā FAN BELT 6 -Remove the worn belt (10) and replace it by performing the relevant procedures described in the engine work- shop manual. [*1] RKTA0561 10 Installation ā¢ To install, reverse the removal procedure. [*1] a Tension the belt by performing the belt tensioning procedure described in the engine workshop man- ual (code WHBMNEF000).
- 12. REMOVAL AND INSTALLATION WH6 - WH7 30-24 RADIATOR-EXCHANGER ASSEMBLY RADIATOR-EXCHANGER ASSEMBLY Removal 1 -Unscrew the cap (1) and drain the coolant liquid. [*1] 6 Coolant liquid: 20 l approx. RKTA0541 1 2 -Loosen and remove the screws (2) retaining the clamps (3). 3 -Disconnect the hose (5) connecting to the expansion tank from the cap (4). RKTA0570 3 4 5 2 3 4 -Disconnect and remove the engine air intake hose (6). RKTA0451 6 5 -Disconnect the coolant liquid inlet hose (7) from the ra- diator. RKTA0580 7
- 13. REMOVAL AND INSTALLATION WH6 - WH7 30-25 RADIATOR-EXCHANGER ASSEMBLY 6 -Disconnect the coolant liquid outlet hose (9) from the ra- diator (8). RKTA0590 8 9 7 -Disconnect the transmission oil inlet and outlet hoses (10) from the exchanger. [*2] a Mark the hoses to avoid mixing them up during in- stallation. a Immediately cap the hoses and plug the holes to prevent contaminants from entering the passages. RKTA0600 10 8 -Remove the retaining screws and remove the fan guard (11). RKTA0531 11 9 -Loosen the screws (12), (13); remove the screws (12) and disengage the radiator (8) from the brackets (14). RKTA0610 13 8 14 12
- 14. REMOVAL AND INSTALLATION WH6 - WH7 30-26 RADIATOR-EXCHANGER ASSEMBLY 10 -Loosen and remove the lower nuts (15) retaining the anti-vibration supports (16). RKTA0551 15 16 11 -Turn the radiator over towards the rear of the machine to gain access to the nuts (17) retaining the fan (18). 12 -Remove the fan. 13 -Connect the radiator assembly to a hoist and remove it from the machine. 4 Radiator assembly: 30 kg. approx. RKTA0562 17 18 Installation ā¢ To install, reverse the removal procedure. [*1] a Carry out the coolant liquid filling procedure. 5 Coolant liquid: 20 l approx. [*2] a Top up the transmission oil.
- 15. REMOVAL AND INSTALLATION WH6 - WH7 30-27 MUFFLER MUFFLER Removal 1 -Remove both lengths of the exhaust duct. (For details, see "EXHAUST PIPE"). 2 -Using acoupleof belts, try to support the muffler(1) tem- porarily. 3 -Disconnect the support (3) from the muffler support (2). RKTA0620 3 1 2 4 -Loosen and remove the rear screws (4) along with their respective washers. 5 -Loosen and remove the supportās front screws, remove their respective washers and remove the muffler (1) to- gether with its support (2). RKTA0630 1 2 4 Installation ā¢ To install, reverse the removal procedure.
- 16. REMOVAL AND INSTALLATION WH6 - WH7 30-28 BATTERY ā BATTERY TRAY BATTERY ā BATTERY TRAY Removal ā¢ Battery 1 -Lifttheterminalshields (1) and disconnectthecables(2) and (3).[*1] k Disconnect the negative (ā) cable first, and then the positive (+) cable. RKTA0640 1 3 3 2 + + + + + 2 -Loosen the nuts (4) until you are able to remove the bracket (5) and the battery retaining rods. RKTA0650 4 4 5 3 -Using the handles provided, remove the battery (6). RKTA0660 6 ā¢ Battery tray 1 -Disconnect the washer pump connectors (7), (8). a Record the positions for connection. 2 -Mark and then disconnect the feed pipes (9). 3 -Release the strap (10) and remove the tank (11). RKTA0670 10 11 7 8 9
- 17. REMOVAL AND INSTALLATION WH6 - WH7 30-29 BATTERY ā BATTERY TRAY 4 -Loosen and remove the screws (12), nuts and washers retaining the surge tank (13). 5 -Remove the tank and position the tanks aside. RKTA0401 12 13 12 6 -Loosen and remove the screw (14) and the nut retaining the converter breather tube (15). RKTA0680 15 14 7 -Loosen and remove the screws (16) together with their respective washers and remove the battery tray (17). RKTA0690 16 17 Installation ā¢ To install, reverse the removal procedure. [*1] a Connect the positive (+) terminal first, and then the negative (ā) terminal.
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- 19. REMOVAL AND INSTALLATION WH6 - WH7 30-30 CYLINDER HEAD CYLINDER HEAD Removal k Disconnect the cable from the negative (ā) battery ter- minal. 1 -Drain the coolant liquid. 6 Coolant liquid: 20 l approx. 2 -Disconnect the wiring (1) connecting to the coolant liq- uid temperature sensor (2) and disengage it from the tie- straps. 3 -Disconnect the wiring (3) from the thermostart (4). RKTA0701 1 2 3 4 4 -Disconnect the oil vapour bleed hose (6) from the valve (5). RKTA0442 5 6 5 -Disconnect or remove: a - the 1st length of the exhaust pipe. b - the turbocompressor. c - the coolant liquid surge tank. d - The fan guard, the fan and the generator belt. e - Only if equipped: the air conditioner compressor complete with support. (For details, see the relevant section for each compo- nent). 6 -Disconnect the feed hose (7) to the radiator from the cyl- inder head. RKTA0580 7
- 20. REMOVAL AND INSTALLATION WH6 - WH7 30-31 CYLINDER HEAD 7 -Disconnect the cab heating feed hose (8) from the cyl- inder head. 8 -Remove the cylinder head and/or replace the cylinder head gasketbyfollowingtheinstructionsgivenintheen- gine workshop manuals (code WHBMNEF000). RKTA0710 8 Installation ā¢ Install the cylinder head by following the instructions giv- en in the engine workshop manuals (code WHBMNEF000) and the reverse order for the parts con- nected to it. 1 -Carry out the coolant liquid filling procedure. 5 Coolant liquid: 20 l approx.
- 21. REMOVAL AND INSTALLATION WH6 - WH7 30-32 INJECTORS INJECTORS Removal 1 -Disengage the feed pipes (1) to the injectors from the wire harness straps and from the retaining clamps. 2 -Perform all the preliminary valve adjusting procedures described, without removing the valve covers. RKTA0720 1 1 3 -Disconnect and remove the engine air intake hoses (2), (3), and the centre support (4). 4 -Remove the injectors in accordance with the instruc- tions given in the engine workshop manual (code WHBMNEF000). RKTA0461 4 2 3 Installation ā¢ To install, reverse the removal procedure.