KOMATSU BACKHOE LOADER WB97R-5E0 SERVICE REPAIR MANUAL
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KOMATSU BACKHOE LOADER WB97R-5E0 SERVICE REPAIR MANUAL
LANGUAGE:ENGLISH
PAGES:518
DOWNLOADABLE:YES
FILE TYPE:PDF
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KOMATSU BACKHOE LOADER WB97R-5E0 SERVICE REPAIR MANUAL
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 workshop.
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 ADJUSTMENTS
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.
REMOVAL AND INSTALLATION
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.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU BACKHOE LOADER WB97R-5E0 SERVICE REPAIR MANUAL
CONTENTS.................................................................................................... 3 SAFETY...................................................................................................... 5 FOREWORD.................................................................................................... 7 HOW TO READ THE SHOP MANUAL................................................................................. 8 HOISTING INSTRUCTIONS....................................................................................... 9 STANDARD TIGHTENING TORQUE.................................................................................. 10 COATING MATERIALS........................................................................................... 12 ELECTRIC.................................................................................................... 13 WEIGHT TABLE................................................................................................ 14 TABLE OF OIL AND COOLANT QUANTITIES......................................................................... 15 CONVERSION TABLE............................................................................................ 17 10 STRUCTURE AND FUNCTION................................................................................... 25 POWER TRAIN............................................................................................. 26 TRANSMISSION (4WD)...................................................................................... 28 TRANSMISSION............................................................................................ 30 CONTROL VALVE BLOCK..................................................................................... 32 DRIVE SHAFTS............................................................................................ 33 FRONT AXLE.............................................................................................. 35 REAR AXLE............................................................................................... 38 HYDRAULIC PUMP.......................................................................................... 42 8-SPOOL CONTROL VALVE................................................................................... 56 10-SPOOL CONTROL VALVE.................................................................................. 64 CLSS.................................................................................................... 73 STEERING UNIT........................................................................................... 94 PPC VALVES.............................................................................................. 95 PPC VALVE (BACKHOE CONTROLS)............................................................................110 SOLENOID VALVE GROUP (EV1)..............................................................................116 HAMMER AND JIG ARM SOLENOID VALVE.......................................................................117 HAMMER SOLENOID VALVE...................................................................................118 JIG ARM SOLENOID VALVE..................................................................................119 JIG ARM AND SIDE DIGGING BOOM SOLENOID VALVE............................................................120 JIG ARM AND 2-WAY ATTACHMENT SOLENOID VALVE.............................................................121 SIDE DIGGING BOOM SOLENOID VALVE........................................................................122 2-WAY ATTACHMENT SOLENOID VALVE.........................................................................123 SAFETY VALVES...........................................................................................124 SHOVEL CYLINDERS........................................................................................128 BACKHOE CYLINDERS.......................................................................................130 AIR-CONDITIONING UNIT...................................................................................134 OPERATION OF THE AIR CONDITIONING UNIT..................................................................135 20 TESTING AND ADJUSTMENTS..................................................................................137 NORMAL OR STANDARD TECHNICAL DATA.......................................................................138 SPECIAL TOOLS...........................................................................................153 VALVE CLEARANCE ADJUSTING...............................................................................154 ENGINE SPEED TESTS......................................................................................155 TENSIONING THE AIR- CONDITIONING COMPRESSOR BELT........................................................156 BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE..............................................157 ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER................................................159 ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...................................................................161 BRAKING SYSTEM CHECKS...................................................................................162 PARKING BRAKE ADJUSTMENT................................................................................164 CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT......................................165 CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES................................................167 SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES..................................................170 CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE. ADJUSTING THE LS VALVE.............................172 CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY PRESSURE....................................................173 ADJUSTING THE PC VALVE..................................................................................174 TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....................................................175 CHECKING FOR LEAKS IN THE STEERING CYLINDERS............................................................176 TESTING PRESSURES IN THE POWER TRAIN GROUP..............................................................177 TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES..............................................179 JIG ARM CLEARANCE ADJUSTMENT............................................................................180 ANALYSIS OF CAUSES HYDRAULIC DRIFT......................................................................182 TESTING THE AIR-CONDITIONING UNIT.......................................................................187 EMPTYING THE AIR-CONDITIONING UNIT......................................................................189 TROUBLESHOOTING.........................................................................................190 30 REMOVAL AND INSTALLATION.................................................................................203 HOW TO READ THE MANUAL..................................................................................204 PRECAUTIONS TO BE TAKEN WHILE WORKING...................................................................205 SPECIAL TOOLS...........................................................................................206 ENGINE HOOD.............................................................................................210 FRONT GUARD.............................................................................................211 RADIATOR GROUP - INTERCOOLER............................................................................212 INTERCOOLER.............................................................................................215 CONDENSER (For machines equipped with an air-conditioning unit).........................................217 EXHAUST PIPE............................................................................................218 MUFFLER.................................................................................................219 AIR FILTER..............................................................................................220 ENGINE BELT.............................................................................................221 TURBOCHARGER............................................................................................222 AIR-CONDITIONING UNIT COMPRESSOR........................................................................223 AIR-CONDITIONING UNIT COMPRESSOR BELT...................................................................225 FAN AND HEATING GROUP...................................................................................226 BATTERY.................................................................................................231 FUEL TANK...............................................................................................232 STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....233 WORKING BRAKE PUMP GROUP................................................................................235 STEERING UNIT...........................................................................................237 CAB.....................................................................................................239 HYDRAULIC OIL TANK......................................................................................244 PISTON PUMP.............................................................................................249 TRANSMISSION............................................................................................251 CONVERTOR...............................................................................................330 ENGINE..................................................................................................331 CONTROL VALVE...........................................................................................334 FRONT AXLE..............................................................................................337 REAR AXLE...............................................................................................369 SHOVEL PPC VALVE........................................................................................410 SHOVEL LIFT CYLINDERS...................................................................................411 SHOVEL DUMP CYLINDERS...................................................................................413 SHOVEL..................................................................................................415 FRONT WORKING EQUIPMENT.................................................................................416 BACKHOE PPC VALVES......................................................................................418 PPC VALVE SUPPORT RELEASE CABLES........................................................................419 PPC VALVE SUPPORT RETURN GAS SPRING.....................................................................421 SOLENOID VALVE GROUP (servocontrol and optional attachment).............................................423 BACKHOE BOOM CYLINDER...................................................................................424 ARM CYLINDER............................................................................................426 JIG ARM CYLINDER........................................................................................428 OUTRIGGER CYLINDER......................................................................................429 BACKHOE SWING CYLINDERS.................................................................................431 BACKHOE BUCKET CYLINDER.................................................................................433 BACKHOE BOOM SAFETY CYLINDER............................................................................435 CYLINDER................................................................................................436 BACKHOE WORKING EQUIPMENT...............................................................................444 BACKHOE BUCKET..........................................................................................446 BACKHOE BOOM CYLINDER...................................................................................447 ARM.....................................................................................................448 JIG ARM.................................................................................................449 2nd ARM.................................................................................................450 2nd ARM GUIDES..........................................................................................451 BACKHOE SWING BRACKET...................................................................................452 COMPLETE BACKHOE BACKFRAME..............................................................................453 BACKFRAME LOCK PISTONS..................................................................................455 40 STANDARD MAINTENANCE.....................................................................................457 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...........................................................458 TRANSMISSION............................................................................................460 FRONT AXLE..............................................................................................463 REAR AXLE...............................................................................................467 HYDRAULIC PUMP..........................................................................................471 CONTROL VALVE...........................................................................................473 PPC VALVES..............................................................................................489 SHOVEL CYLINDERS........................................................................................491 BACKHOE CYLINDERS.......................................................................................493 FRONT WORKING EQUIPMENT.................................................................................496 SWING BRACKET...........................................................................................498 BACKHOE WORKING EQUIPMENT...............................................................................500 90 DIAGRAMS AND DRAWINGS....................................................................................503 HYDRAULIC CIRCUIT DIAGRAM FROM S/N F80211 TO S/N F80359 AND FROM S/N F80362 TO S/N F80399...............505 HYDRAULIC CIRCUIT DIAGRAM FROM S/N F80360 TO S/N F80361 AND FROM S/N F80400 AND UP......................507 HYDRAULIC CIRCUIT DIAGRAM - OPTIONAL....................................................................509 ELECTRICAL CIRCUIT DIAGRAM (1/3)........................................................................511 ELECTRICAL CIRCUIT DIAGRAM (2/3)........................................................................513 ELECTRICAL CIRCUIT DIAGRAM (3/3)........................................................................515
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