Komatsu WA100-1 Wheel Loader Shop Manual SEBM04160105 PDF

Description

Komatsu WA100-1 Wheel Loader Shop Manual SEBM04160105 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA100-1 Wheel Loader Shop Manual SEBM04160105 – PDF DOWNLOAD 

Language : English
Pages : 626
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA100-1 Wheel Loader Shop Manual SEBM04160105 – PDF DOWNLOAD 

MACHINE MODEL  SERIAL No.
WA100-1                   10001 and up

COVER 1
CONTENTS 2
10 ENGINE 39
11 STRUCTURE AND FUNCTION 39
ENGINE MOUNT 40
RADIATOR AND COOLER 41
FUEL TANK AND PIPING 43
ENGINE CONTROL 44
12 TESTING AND ADJUSTING 45
STANDARD VALUE TABLE 46
TOOL LIST FOR TESTING AND ADJUSTING 47
ADJUSTING VALVE CLEARANCE 48
MEASURING COMPRESSION PRESSURE 49
TESTING AND ADJUSTING FUEL INJECTION TIMING 50
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE 51
MEASURING BLOW-BY PRESSURE 52
TESTING AND ADJUSTING FAN BELT TENSION 53
MEASURING EXHAUST GAS COLOR 54
MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL 55
13 DISASSEMBLY AND ASSEMBLY 59
STARTING MOTOR 60
REMOVAL 60
INSTALLATION 60
ALTERNATOR 61
REMOVAL 61
INSTALLATION 61
FUEL INJECTION PUMP 62
REMOVAL 62
INSTALLATION 63
WATER PUMP 65
REMOVAL 65
INSTALLATION 66
NOZZLE HOLDER 67
REMOVAL (SERIAL NO 10001-19999) 67
INSTALLATION (SERIAL NO 10001-19999) 67
REMOVAL (SERIAL NO 20001-) 68
INSTALLATION (SERIAL NO 20001-) 68
CYLINDER HEAD 70
REMOVAL 70
INSTALLATION 76
RADIATOR 82
REMOVAL 82
INSTALLATION 85
ENGINE 88
REMOVAL 88
INSTALLATION 94
FUEL TANK 100
REMOVAL 100
INSTALLATION 101
20 POWER TRAIN 103
21 STRUCTURE AND FUNCTION 103
GENERAL 104
HYDRAULIC CIRCUIT FOR POWER TRAIN 106
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 107
FORWARD 1ST 108
TORQUE CONVERTER AND TRANSMISSION PIPING 110
TORQUE CONVERTER CHARGING PUMP 111
TORQUE CONVERTER 112
TORQUE CONVERTER OIL FILTER 114
TORQFLOW TRANSMISSION 116
CLUTCH PACK 119
TRANSMISSION CONTROL VALVE 128
MAIN REGULATOR VALVE 130
TORQUE CONVERTER OIL OUTLET VALVE 131
QUICK RETURN VALVE AND ACCUMULATOR 132
POWER MODULATING FUNCTION 134
ACCUMULATOR VALVE 138
ACTION OF THE CLUTCH CUT-OFF VALVE 139
DRIVE SHAFT 141
AXLE 142
DIFFERENTIAL 144
FINAL DRIVE 148
AXLE MOUNT 150
TIRE AND WHEEL 152
22 TESTING AND ADJUSTING 153
STANDARD VALUE TABLE 154
TOOL LIST FOR TESTING AND ADJUSTING 155
MEASURING ENGINE STALL SPEED 156
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION 158
MEASURING SHIFT LEVER 160
MEASURING VALVE SPOOL OPERATING FORCE AND TRAVEL 161
TROUBLESHOOTING 163
PRECAUTIONS WHEN TROUBLESHOOTING 164
METHOD OF READING TROUBLESHOOTING TABLE 166
PREVENTING RECURRENCE OF TROUBLE 168
TROUBLESHOOTING TABLE 170
1 MACHINE DOES NOT MOVE OFF 170
2 MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF 172
3 LARGE SHOCK WHEN MOVING OFF OR CHANGING GEAR 174
4 LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR 175
5 OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH 176
23 DISASSEMBLY AND ASSEMBLY 177
TORQUE CONVERTER CHARGING PUMP 178
REMOVAL 178
INSTALLATION 178
TORQUE CONVERTER, TRANSMISSION 180
REMOVAL 180
INSTALLATION 190
TORQUE CONVERTER 198
DISASSEMBLY 198
ASSEMBLY 201
TRANSMISSION 204
DISASSEMBLY 204
ASSEMBLY 214
CLUTCH PACK 228
DISASSEMBLY 228
ASSEMBLY 236
TRANSMISSION VALVE 250
REMOVAL 250
INSTALLATION 252
TRANSMISSION CONTROL VALVE 254
DISASSEMBLY 254
ASSEMBLY 258
DRIVE SHAFT 264
DISASSEMBLY 264
ASSEMBLY 266
FRONT AXLE 268
REMOVAL 268
INSTALLATION 270
REAR AXLE 272
REMOVAL 272
INSTALLATION 276
DIFFERENTIAL 282
DISASSEMBLY 282
ASSEMBLY 286
AXLE HOUSING 296
DISASSEMBLY 296
ASSEMBLY 301
24 MAINTENANCE STANDARD 309
TRANSMISSION AND ENGINE MOUNT 310
TORQUE CONVERTER CHARGING PUMP 311
TORQUE CONVERTER 312
TRANSMISSION 314
TRANSMISSION CLUTCH ASSEMBLY 316
TRANSMISSION CONTROL VALVE 318
AXLE 320
DIFFERENTIAL 322
FINAL DRIVE 324
DRIVE SHAFT 325
AXLE MOUNT 326
40 STEERING SYSTEM 329
41 STRUCTURE AND FUNCTION 329
GENERAL 330
HYDRAULIC CIRCUIT FOR STEERING 332
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING 333
OPERATIONS OF STEERING VALVE 334
STEERING VALVE (SERIAL NO 10001-19999) 336
STEERING RELIEF VALVE 338
SAFETY VALVE (WITH SUCTION VALVE) 339
OPERATION OF DEMAND VALVE 341
TWO-WAY RESTRICTOR VALVE 342
STEERING VALVE (SERIAL NO 20001-) 344
PRIORITY VALVE 352
STEERING COLUMN AND GEAR BOX 355
STEERING LINKAGE 356
STEERING CYLINDER 357
CENTER HINGE PIN 358
42 TESTING AND ADJUSTING 359
STANDARD VALUE TABLE 360
TOOL LIST FOR TESTING AND ADJUSTING 360
MEASURING STEERING WHEEL PLAY 361
MEASURING OPERATING FORCE OF STEERING WHEEL 362
OPERATING TIME OF STEERING WHEEL 363
TESTING STEERING LINKAGE 364
ADJUSTING STEERING LINKAGE 365
STEERING OIL PRESSURE 366
TROUBLESHOOTING 367
TROUBLESHOOTING TABLE 368
1 STEERING WHEEL DOES NOT TURN 368
2 STEERING WHEEL IS SLUGGISH 370
3 STEERING WHEEL MOVE UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK 372
4 MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING 372
5 LEFT AND RIGHT TURNING RADII ARE DIFFERENT 372
43 DISASSEMBLY AND ASSEMBLY 375
STEERING GEAR BOX 376
REMOVAL 376
INSTALLATION 377
DISASSEMBLY 378
ASSEMBLY 379
STEERING VALVE 382
REMOVAL 382
INSTALLATION 383
DISASSEMBLY 384
ASSEMBLY 386
PRIORITY VALVE 388
REMOVAL 388
INSTALLATION 389
STEERING VALVE 390
REMOVAL 390
INSTALLATION 391
STEERING CYLINDER 392
REMOVAL 392
INSTALLATION 392
DISASSEMBLY 394
ASSEMBLY 396
CENTER HINGE PIN 400
REMOVAL 400
INSTALLATION 410
44 MAINTENCE STANDARD 421
STEERING VALVE 422
STEERING CYLINDER MOUNT 424
STEERING CYLINDER 425
CENTER HINGE PIN 426
STEERING LINKAGE 428
STEERING COLUMN AND GEAR BOX 429
STEERING COLUMN 430
PRIORITY VALVE 431
50 BRAKE SYSTEM 433
51 STRUCTURE AND FUNCTION 433
GENERAL 434
BRAKE MASTER CYLINDER 436
BRAKE 438
PARKING BRAKE 440
BRAKE CALIPER 442
52 TESTING AND ADJUSTING 443
STANDARD VALUE TABLE 444
TOOL LIST FOR TESTING AND ADJUSTING 445
MEASURING BRAKE PEDAL 446
TESTING AND ADJUSTING OF BRAKE PEDAL LINKAGE 447
BRAKE PERFORMANCE 449
CHECKING BRAKE PISTON LEAKAGE 450
MEASURING WEAR OF BRAKE DISC 451
AIR BLEEDING FROM BRAKE LINE 452
PARKING BRAKE PERFORMANCE 453
CHECKING AND ADJUSTING PARKING BRAKE 454
MEASURING CLEARANCE 456
TROUBLESHOOTING 457
TROUBLESHOOTING TABLE 458
1 BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE 458
2 BRAKE CANNOT BE RELEASED OR DRAGS 459
53 DISASSEMBLY AND ASSEMBLY 461
MASTER CYLINDER 462
REMOVAL 462
INSTALLATION 463
DISASSEMBLY 464
ASSEMBLY 465
PARKING BRAKE 466
REMOVAL 466
INSTALLATION 468
PARKING BRAKE PAD 470
REMOVAL 470
INSTALLATION 471
54 MAINTENANCE STANDARD 473
BRAKE MASTER CYLINDER 474
BRAKE 475
PARKING BRAKE 476
60 WORK EQUIPMENT SYSTEM 477
61 STRUCTURE AND FUNCTION 477
GENERAL 478
HYDRAULIC CIRCUIT (SERIAL NO 10001-19999) 480
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO 10001-19999) 481
HYDRAULIC CIRCUIT (SERIAL NO 20001-) 482
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO 20001-) 483
DUMP AND LIFT CONTROL LEVER LINKAGE 484
BUCKET LINKAGE 486
BUCKET POSITIONER AND BOOM KICK-OUT 488
HYDRAULIC TANK 489
OIL FILTER BYPASS VALVE 492
BREATHER 492
HYDRAULIC AND STEERING PUMP 493
MAIN CONTROL VALVE 494
RELIEF VALVE 496
SAFETY VALVE 497
SUCTION VALVE 498
HYDRAULIC CYLINDER 505
62 TESTING AND ADJUSTING 507
STANDARD VALUE TABLE 508
TOOL LIST FOR TESTING AND ADJUSTING 509
MEASURING DUMP AND LIFT CONTROL LEVERS 510
ADJUSTING DUMP AND LIFT CONTROL LEVERS 511
MEASURING DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL 512
MEASURING HYDRAULIC PRESSURE 513
MEASURING LIFT ARM AND BUCKET 515
MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET 516
ADJUSTING BUCKET POSITIONER 517
ADJUSTING BOOM KICK-OUT 518
TROUBLESHOOTING 519
TROUBLESHOOTING TABLE 520
1 LIFT ARM DOES NOT RISE 520
2 LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER 521
3 LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT 522
4 BUCKET CANNOT BE HOLD DOWN WITH LIFT ARM CYLINDER 522
5 LIFT ARM HAS LARGE HYDRAULIC DRIFT 522
6 LIFT ARM MOVEMENT IS UNSTEADY DURING WORK 522
7 LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “RAISE” 522
8 BUCKET DOES NOT TILT BACK 523
9 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER 524
10 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK 525
11 BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER 525
12 BUCKET HAS LARGE HYDRAULIC DRIFT 525
13 BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD 525
14 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “TILT BACK” 525
15 CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY 526
63 DISASSEMBLY AND ASSEMBLY 527
HYDRAULIC TANK 528
REMOVAL 528
INSTALLATION 529
HYDRAULIC FILTER 530
REMOVAL 530
INSTALLATION 530
HYDRAULIC-STEERING PUMP 531
REMOVAL 531
INSTALLATION 531
MAIN CONTROL VALVE 532
REMOVAL 532
INSTALLATION 534
DISASSEMBLY 536
ASSEMBLY 538
DUMP CYLINDER 540
REMOVAL 540
INSTALLATION 542
LIFT CYLINDER 544
REMOVAL 544
INSTALLATION 545
LIFT AND DUMP CYLINDER 546
DISASSEMBLY 546
ASSEMBLY 548
WORK EQUIPMENT 552
REMOVAL 552
INSTALLATION 555
COUNTERWEIGHT 558
REMOVAL 558
INSTALLATION 558
64 MAINTENANCE STANDARD 559
MAIN CONTROL VALVE 560
DUMP CYLINDER 562
LIFT CYLINDER 563
WORK EQUIPMENT 564
BUCKET POSITIONER AND BOOM KICK-OUT 566
BUCKET 567
HYDRAULIC AND STEERING PUMP 568
80 ELECTRIC AND ELECTRONIC SYSTEM 569
81 STRUCTURE AND FUNCTION 569
CLUSTER GAUGE 570
PROXIMITY SWITCH 572
ENGINE STARTING CIRCUIT 574
ENGINE STOP CIRCUIT 575
PREHEATING CIRCUIT 576
PREHEATING WITH STARTING SWITCH 576
ELECTRICAL WIRING DIAGRAM 577
ELECTRICAL WIRING DIAGRAM CIRCUIT 578
SENSOR 580
83 DISASSEMBLY AND ASSEMBLY 585
INSTRUMENT PANEL 586
REMOVAL 586
INSTALLATION 587
90 OTHERS 589
91 STRUCTURE AND FUNCTION 589
CAB 590
AIR CONDITIONER (OPTION) 591
AIR CONDITIONER PIPING 591
AIR CONDITIONER WIRING DIAGRAM 592
AIR CONDITIONER ELECTRIC CIRCUIT 592
AIR CONDITIONER UNIT 593
AIR CONDITIONER COMPRESSOR 594
AIR CONDITIONER CONDENSOR 594
AIR CONDITIONER DRY RESERVOIR 595
93 DISASSEMBLY AND ASSEMBLY 597
CAB 598
REMOVAL 598
INSTALLATION 599
97 GEAR PUMP 601
GENERAL 601
GENERAL 602
PRINCIPLE OF OPERATION 603
PRESSURE LOADED TYPE GEAR PUMP 606
FIXED SIDE PLATE TYPE GEAR PUMP 608
SA SERIES 609
STRUCTURE 610
TESTING AND ADJUSTING 613
DISASSEMBLY 616
ASSEMBLY 620
MAINTENANCE STANDARD 625

DESCRIPTION:

Komatsu WA100-1 Wheel Loader Shop Manual SEBM04160105 – PDF DOWNLOAD 

MACHINE MODEL  SERIAL No.
WA100-1                   10001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

S.V 29/12/24