Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09002 – PDF DOWNLOAD

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Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09002 – PDF DOWNLOAD

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Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09002 – PDF DOWNLOAD

Language : English
Pages : 1009
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09002 – PDF DOWNLOAD

          Model:                    Serial number:

• WA70M-8E0          H71511 and up

VENBM09002 WA70M-8E0 1
INDEX AND FOREWORD 3
ABBREVIATION LIST . 4
List of abbreviations used in the text 4
List of abbreviations used in the circuit diagrams 9
FOREWORD, SAFETY, BASIC INFORMATION . 10
HOW TO READ THE SHOP MANUAL . 10
Composition of the shop manual 10
Symbols . 12
Signal word . 12
Unit 12
SAFETY NOTICE FOR OPERATION . 13
Safety matters 13
General precautions . 14
Precautions for preparatory work 15
Precautions during work . 15
Precautions for slinging work and making signals 17
Precautions for using mobile crane 20
Precautions for using overhead traveling crane 20
Selecting wire ropes 21
PRECAUTIONS TO PREVENT FIRE . 23
Fire caused by fuel, oil, coolant or window washer fluid 23
Fire caused by accumulation or attachment of flammable material . 23
Fire coming from electric wiring 23
Fire caused by piping . 24
Fire around the machine due to highly heated exhaust gas 24
Explosion caused by lighting equipment 24
ACTIONS IF FIRE OCCURS 25
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 26
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 27
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 28
Select an appropriate workplace . 28
Disassembly and maintenance work in the field . 28
Sealing of openings (prevention of flowing out of oil) 28
Preventing intrusion of foreign materials during refilling 29
Replacing hydraulic oil while its temperature is high . 29
Avoid reusing the hydraulic oil and lubricating oil . 29
Flushing operation 29
Cleaning operation 30
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 31
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 42
Defective contact of connectors (defective contact between male and female connectors) 42
Defective crimping or soldering of connectors . 43
Disconnection in wiring . 43
Water entering the connector by high-pressure jetting . 43
Entry of water, dirt, or dust when disconnecting a connector 43
Oil, mud, or dust stuck to connector 44
Select an appropriate workplace . 45
Sealing the opening . 45
How to clean parts when dirt is stuck . 45
Precautions for replacing fuel filter cartridge . 45
Select an appropriate workplace . 46
Sealing the opening . 46
PRACTICAL USE OF KOMTRAX 47
Merit of using KOMTRAX 47
How to make a full use of KOMTRAX . 48
How to operate KOMTRAX 48
Disconnecting connectors 49
Connecting connectors . 50
Drying wiring harness . 52
Handling controller . 53
Method for disconnecting Deutsch connector 54
Method for connecting Deutsch connector . 54
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) . 55
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 55
Method for disconnecting slide lock type connector (FRAMATOME-24) . 55
Method for connecting slide lock type connector (FRAMATOME-24) 56
Method for disconnecting connector with lock to pull 57
Method for connecting connector with lock to pull . 57
Method for disconnecting connector with lock to push (BOSCH-3) 58
Method for connecting connector with lock to push (BOSCH-3) . 58
Method for disconnecting connector with lock to push (AMP-3) 59
Method for connecting connector with lock to push (AMP-3) . 59
Method for disconnecting connector with lock to push (SUMITOMO-3) . 59
Method for connecting connector with lock to push (SUMITOMO-3) 59
Method for disconnecting connector with lock to push (SUMITOMO-4) . 59
Method for connecting connector with lock to push (SUMITOMO-4) 59
Method for disconnecting connector with housing to rotate . 60
Method for connecting connector with housing to rotate 60
Method for connecting ring terminals and strip fuses to power stud of printed circuit boards 61
HOW TO READ ELECTRICAL WIRE CODE 62
TYPE, SYMBOL, AND MATERIAL 62
COLOR CODES TABLE . 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 64
STANDARD DIMENSION AND TOLERANCE 64
STANDARD CLEARANCE AND STANDARD VALUE . 65
STANDARD INTERFERENCE . 65
REPAIR LIMIT AND ALLOWABLE VALUE OR ALLOWABLE DIMENSION . 65
ALLOWABLE CLEARANCE . 66
ALLOWABLE INTERFERENCE 66
STANDARD TIGHTENING TORQUE TABLE 67
CONVERSION TABLE 75
METHOD OF USING THE CONVERSION TABLE 75
EXAMPLES OF USING THE CONVERSION TABLE TO CONVERT A UNIT FROM MM TO IN 75
TEMPERATURE . 79
SPECIFICATIONS 81
DIMENSIONS, WEIGHTS AND OPERATING DATA 82
SPECIFICATIONS 84
WEIGHT TABLES . 85
LUBRICANTS AND OPERATING MEDIUMS 86
BASIC PROCEDURES OF MAINTENANCE . 88
OIL . 88
FUEL 88
COOLANT . 89
GREASE 89
STORING OIL AND FUEL 89
FILTERS . 90
OUTLINE OF ELECTRIC SYSTEM 90
TIGHTENING TORQUE LIST – METRIC SCREWS AND NUTS . 91
STRUCTURE AND FUNCTION 93
ABBREVIATION LIST . 97
List of abbreviations used in the text 97
List of abbreviations used in the circuit diagrams 102
ELECTRICAL SYSTEM . 103
BOOT-UP SYSTEM 104
LAYOUT DRAWING OF BOOT-UP SYSTEM 104
AROUND THE CAB AND FLOOR 105
BATTERY DISCONNECT SWITCH . 106
FUNCTION OF BATTERY DISCONNECT SWITCH . 106
PREHEATING SYSTEM . 108
FUNCTION OF AUTOMATIC PREHEATING SYSTEM . 109
OPERATION OF AUTOMATIC PREHEATING SYSTEM 109
ENGINE SYSTEM . 110
LAYOUT DRAWING OF ENGINE SYSTEM . 110
COOLING SYSTEM 111
LAYOUT DRAWING OF COOLING SYSTEM 111
SPECIFICATIONS OF COOLING SYSTEM 112
COOLING FAN CONTROL SYSTEM 113
FUNCTION OF COOLING FAN CONTROL SYSTEM 114
COOLING FAN REVERSE ROTATION FUNCTION (Option) 114
COMPONENT PARTS OF COOLING SYSTEM . 115
STRUCTURE OF COOLING FAN MOTOR 115
CONTROL SYSTEM 116
AROUND THE CAB AND FLOOR 117
MACHINE MONITOR SYSTEM 118
MACHINE MONITOR SYSTEM DIAGRAM 118
KOMTRAX SYSTEM 119
KOMTRAX SYSTEM DIAGRAM 119
FUNCTION OF KOMTRAX SYSTEM 119
COMPONENT PARTS OF CONTROL SYSTEM . 120
MACHINE MONITOR . 120
Function of KOMTRAX terminal 130
HST CONTROLLER 132
Structure of HST controller . 132
Real time monitoring function . 132
Self-diagnosis function . 132
CAN TERMINATING RESISTOR 136
Function of CAN terminating resistor 136
ENGINE CONTROLLER . 137
Real time monitoring function . 137
Self-diagnosis function . 137
ACCELERATOR PEDAL . 138
Acceleration signal . 138
Idling validation signal 138
Output Characteristics 139
HYDRAULIC SYSTEM 140
Structure of hydraulic tank . 141
Specifications of hydraulic tank 141
Structure of main control valve (STD) . 143
POWER TRAIN SYSTEM 146
OPERATION OF POWER TRAIN SYSTEM . 147
FUNCTION OF THE CLOSED CIRCUIT SYSTEM . 149
SPECIFICATIONS OF THE HST SYSTEM 149
STRUCTURE OF THE HST SYSTEM . 150
20km/h without SpeedControl . 150
COMPONENT PARTS OF POWER TRAIN SYSTEM . 151
Structure of drive shaft 151
Function of drive shaft . 151
Structure of HST pump . 152
Operation of HST pump . 153
Components of HST pump 154
HST motor . 156
Structure of transfer box . 157
Function of transfer box 158
Structure of front axle . 159
Structure of rear axle 160
Function of differential 160
Function of towing system . 162
WORK EQUIPMENT SYSTEM . 163
Layout of work equipment system . 163
WORK EQUIPMENT LOCK SYSTEM 165
ECSS (Option) . 166
Function of ECSS 166
Operation of ECSS . 166
RETURN TO DIG (option) 167
Structure . 167
Function 167
Main control valve 168
Emergency lowering 168
Loader Linkage with quick-coupler . 170
STEERING SYSTEM . 172
STEERING COLUMN . 173
Structure of steering column 173
General view 173
PRIORITY VALVE 176
ORBITROL-VALVE 177
STEERING RELIEF VALVE . 178
BRAKE SYSTEM 179
LAYOUT DRAWING OF BRAKE SYSTEM 179
SERVICE BRAKE ASSEMBLY 180
Inching Function 180
PARKING BRAKE ASSEMBLY 181
STRUCTURE OF 181
UNDERCARRIAGE AND FRAME . 182
Rear axle mount . 183
Frame, axle mount and center hinge pin 184
TIRE 185
Structure of radial tire 185
General view 185
Structure . 185
Structure of bias tire 186
General view 186
Structure . 186
WORK EQUIPMENT 187
STRUCTURE OF WORK EQUIPMENT . 187
STRUCTURE OF BUCKET . 188
General view and sectional view . 188
CAB AND ITS ATTACHMENTS . 189
ROPS FOPS CAB . 189
Structure of ROPS FOPS cab 189
Function of ROPS FOPS cab . 190
CAB MOUNT . 191
Structure of cab mount 191
General view 191
Function of cab mount . 191
STANDARD VALUE TABLE 203
ABBREVIATION LIST . 204
List of abbreviations used in the text 204
List of abbreviations used in the circuit diagrams 209
STANDARD VALUE TABLE 210
Standard value table for engine . 210
Standard value table for chassis 211
TEST CERTIFICATE 213
TESTING AND ADJUSTING . 215
ABBREVIATION LIST . 219
List of abbreviations used in the text 219
List of abbreviations used in the circuit diagrams 225
TEST ENGINE WITH SOFTWARE TOOL 226
CONNECTION OF A COMPUTER TO THE MACHINE . 226
ENGINE AND COOLING SYSTEM . 228
TEST ENGINE SPEED . 228
Method for testing engine speed . 228
Method for testing engine low idle speed 228
Method for testing engine high idle speed . 229
Method for testing engine speed HST stall . 230
Method for testing engine speed at hydraulic stall 231
Method for testing engine speed at full stall (HST stall and hydraulic stall) . 232
TEST EXHAUST GAS COLOUR . 234
Testing tool for exhaust gas colour . 234
TEST AND ADJUST VALVE CLEARANCE . 236
METHOD FOR TESTING AND ADJUSTINGVALVE CLEARANCE . 237
TEST COMPRESSION PRESSURE . 238
METHOD FOR TESTING COMPRESSION PRESSURE . 238
Compression pressure inspection procedures 239
Injector reassembly procedures 240
TEST ENGINE OIL PRESSURE 241
METHOD FOR TESTING ENGINE OIL PRESSURE 241
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 242
TEST FUEL CIRCUIT FOR LEAKAGE . 243
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 243
Testing method of fuel circuit for leakage at engine stopped 243
Testing method of fuel circuit for leakage at engine low idle . 244
Testing method of fuel circuit for leakage at engine high idle 244
HANDLE NO-INJECTION CRANKING OPERATION 245
TEST DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 246
METHOD FOR TESTING DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 246
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 247
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 247
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS . 248
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS . 248
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 249
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 249
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 250
TEST ALTERNATOR BELT 251
METHOD FOR TESTING ALTERNATOR BELT 251
POWER TRAIN . 252
TEST AND ADJUST HST PRESSURE CUT OFF 252
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 253
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 253
STEERING SYSTEM . 254
Operating time for steering wheel . 254
Operating force of steering wheel . 255
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE . 256
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 257
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 258
BLEED AIR FROM STEERING CYLINDER CIRCUIT 259
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 259
BLEED AIR FROM BRAKE CIRCUIT 260
TEST BRAKING PERFORMANCE 262
MEASURING THE STOPPING DISTANCE . 262
TEST AND ADJUST BRAKE PEDAL . 263
TEST WEAR OF WHEEL BRAKE PADS . 264
TEST PARKING BRAKE PERFORMANCE 265
HYDRAULIC SYSTEM 266
Release the remaining pressure from small accumulator for safety valves (option) 266
Releasing the remaining pressure in ECSS 268
TEST AND ADJUST WORK EQUIPMENT PRESSURE . 269
TEST BOOST PRESSURE . 270
TESTING AND ADJUSTING COOLING FAN SPEED . 271
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE . 273
METHOD FOR TESTING THE ECSS ACCUMULATOR NITROGEN GAS PRESSURE . 274
METHOD FOR CHARGING THE ECSS ACCUMULATOR WITH NITROGEN GAS 275
ELECTRICAL SYSTEM . 277
SET AND ADJUST EACH EQUIPMENT . 277
SET AND OPERATE MACHINE MONITOR . 278
Switch panel 278
Operator mode and service mode of machine monitor . 279
OPERATOR MODE . 281
Setting usage limitation (password) . 281
Change password . 282
SERVICE MODE 284
METHOD FOR OPERATING SERVICE MODE . 284
Table of self-define monitoring . 287
ABNORMALITY RECORD MENU . 296
Method for cleaning abnormality record 299
DEFAULT MENU 309
METHOD FOR SETTING WITH DEFAULT SETTING MENU (OPTION SELECTION) . 311
ADJUSTMENT MENU . 315
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (T/C DEVICE CALIBRATION) 315
HANDLE BATTERY DISCONNECT SWITCH 318
TEST DIODES . 320
TROUBLESHOOTING . 323
ABBREVIATION LIST . 327
List of abbreviations used in the text 327
List of abbreviations used in the circuit diagrams 333
RELATED INFORMATION ON TROUBLESHOOTING 334
GENERAL TROUBLESHOOTING POINTS 334
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 336
CHECKS BEFORE TROUBLESHOOTING . 338
Engine, lubricating oil and coolant . 338
Hydraulic and mechanical equipment 338
Electric equipment 339
Exterior 339
Interior 339
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 340
WALK-AROUND CHECK . 340
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 342
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 343
CONNECTOR LOCATION LIST . 345
CONNECTOR CONTACT IDENTIFICATION 354
SPARE FUSES AND RELAY . 391
USB socket on central electric board (CEB) 396
FAILURE CODES TABLE . 399
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF HST-CONTROLLER CODE) 417
POWER ON 418
8.2.1 Documentation of Power On (PwrOn) . 418
8.2.1 – 2 Interface . 418
8.2.1 – 3 Description . 419
8.2.1 – 3.3 State 2: Check sensor supply voltages . 422
8.2.1 – 3.4 State 3: Check hardware monitoring errors . 422
8.2.1 – 3.5 State 4: Check first application specific start condition . 422
8.2.1 – 3.6 State 5: Check central switch . 422
8.2.1 – 3.7 State 6: Configure safouts 423
8.2.1 – 3.8 State 7: Check safouts 423
8.2.1 – 3.9 State 8: Check diesel engine speed 423
8.2.1 – 3.10 State 9: Enable sensor supply monitoring . 424
8.2.1 – 3.11 State 10: Check hardware monitoring errors . 424
8.2.1 – 3.12 State 11: Check second applications specific start condition . 424
8.2.1 – 3.12 State 11: Check second applications specific start condition . 424
8.2.1 – 3.13 State 12: Run 424
8.2.1 – 3.14 Diagnosis Configuration Notes 424
8.2.1 – 4 Input Signals . 425
8.2.1 – 5 Parameters 426
8.2.1 – 6 Output Signals 426
8.2.1 – 7 Error Information . 426
Abbreviations for Failure Code (HST-controller) . 428
FAILURE CODE (#R0CIB) . 429
FAILURE CODE (#R0CKB) . 430
FAILURE CODE (#R0CLB) . 431
FAILURE CODE (#R0CMB) . 432
FAILURE CODE (#R0CPV) . 433
FAILURE CODE (#R0CQB) . 434
FAILURE CODE (#R0CRB) . 435
FAILURE CODE (#R0CSB) . 436
FAILURE CODE (#R0CTB) . 437
FAILURE CODE (#R0CWB) . 438
FAILURE CODE (#R0JLB) . 439
FAILURE CODE (#R0JMB) . 440
FAILURE CODE (#R0JNB) . 441
FAILURE CODE (#R0JOB) . 442
FAILURE CODE (#R0JPB) . 443
FAILURE CODE (#R0QR2) . 444
FAILURE CODE (#R0QS2) . 445
FAILURE CODE (#R0QT4) . 446
FAILURE CODE (#R0QU3) . 447
FAILURE CODE (#R0QV4) . 448
FAILURE CODE (#R0QY4) . 449
FAILURE CODE (#R0R0V) . 450
FAILURE CODE (#R0R1V) . 451
FAILURE CODE (#R0SHV) . 452
FAILURE CODE (#R0SJV) . 453
FAILURE CODE (#R0XU2) . 454
FAILURE CODE (#R0XU3) . 455
FAILURE CODE (#R0XU4) . 456
FAILURE CODE (#R0XUB) . 457
FAILURE CODE (#R0XV2) . 458
FAILURE CODE (#R0XV3) . 459
FAILURE CODE (#R0XV4) . 460
FAILURE CODE (#R0XVB) . 461
FAILURE CODE (#R0XW2) . 462
FAILURE CODE (#R0XW3) . 463
FAILURE CODE (#R0XW4) . 464
FAILURE CODE (#R0XWB) . 465
FAILURE CODE (#R14W2) . 466
FAILURE CODE (#R14WB) . 467
FAILURE CODE (#R14X2) . 468
FAILURE CODE (#R14XB) . 469
FAILURE CODE (#R14Y3) . 470
FAILURE CODE (#R14YV) . 471
FAILURE CODE (#R14Z2) . 472
FAILURE CODE (#R14ZB) . 473
FAILURE CODE (#R1502) . 474
FAILURE CODE (#R150B) . 475
FAILURE CODE (#R1532) . 476
FAILURE CODE (#R153B) . 477
FAILURE CODE (#R1KWJ) . 478
FAILURE CODE (#R1KWV) . 479
FAILURE CODE (#R1L0B) . 480
FAILURE CODE (#R1L2B) . 481
FAILURE CODE (#R1L4B) . 482
FAILURE CODE (#R1R4B) . 483
FAILURE CODE (#R2690) . 484
FAILURE CODE (#R2691) . 485
FAILURE CODE (#R2694) . 486
FAILURE CODE (#R269B) . 487
FAILURE CODE (#R26B0) . 488
FAILURE CODE (#R26B1) . 489
FAILURE CODE (#R26B4) . 490
FAILURE CODE (#R26BB) . 491
FAILURE CODE (#R26OB) . 492
FAILURE CODE (#R26P0) . 493
FAILURE CODE (#R26P1) . 494
FAILURE CODE (#R26P4) . 495
FAILURE CODE (#R26PB) . 496
FAILURE CODE (#R2BKB) . 497
FAILURE CODE (#R2IPB) . 498
FAILURE CODE (#R2IQB) . 500
FAILURE CODE (#R2IRB) . 502
FAILURE CODE (#R2ITB) . 504
FAILURE CODE (#R2IUB) . 506
FAILURE CODE (#R2J4B) . 508
FAILURE CODE (#R2JK2) . 509
FAILURE CODE (#R2JK9) . 510
FAILURE CODE (#R2JKB) . 511
FAILURE CODE (#R2JKB) . 512
FAILURE CODE (#R2JL2) . 513
FAILURE CODE (#R2JL9) . 514
FAILURE CODE (#R2JLB) . 515
FAILURE CODE (#R2JM2) . 516
FAILURE CODE (#R2JM9) . 517
FAILURE CODE (#R2JMB) . 518
FAILURE CODE (#R2JS2) . 519
FAILURE CODE (#R2JS9) . 520
FAILURE CODE (#R2JSB) . 521
FAILURE CODE (#R2JT2) . 522
FAILURE CODE (#R2JT9) . 523
FAILURE CODE (#R2JTB) . 524
FAILURE CODE (#R2JU2) . 525
FAILURE CODE (#R2JU9) . 526
FAILURE CODE (#R2JUB) . 527
FAILURE CODE (#R94Y2) . 528
FAILURE CODE (#R94YB) . 529
FAILURE CODE (#R9512) . 530
FAILURE CODE (#R951B) . 531
FAILURE CODE (#R968B) . 532
FAILURE CODE (#R9JLB) . 533
FAILURE CODE (#R9Q82) . 534
FAILURE CODE (#R9Q8B) . 535
FAILURE CODE (#R9Q8V) . 536
FAILURE CODE (#R9QDB) . 537
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E- MODE) 538
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) . 556
TROUBLESHOOTING OF ENGINE (S-MODE) 565
S-4 ENGINE STARTABILITY IS POOR . 569
S-9 EXHAUST SMOKE IS BLACK 577
S-12 FUEL CONSUMPTION IS EXCESSIVE 581
S-14 OIL PRESSURE DROPS . 583
S-18 UNUSUAL NOISE IS HEARD . 588
S-19 VIBRATION IS EXCESSIVE . 589
DISASSEMBLY AND ASSEMBLY 593
ABBREVIATION LIST . 595
List of abbreviations used in the text 595
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY . 600
HOW TO READ THIS MANUAL . 600
Reading the work procedures . 600
Reading the symbols . 600
Reading the signal word . 601
Reading the unit 601
COATING MATERIALS LIST 602
Adhesive 602
Liquid gasket . 603
Molybdenum disulfide lubricant 603
Seizure prevention compound . 604
Grease 604
Primer 605
Adhesive 605
Caulking material . 605
ENGINE AND COOLING SYSTEM . 606
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY . 606
Removal of supply pump assembly . 606
Reassembly of supply pump . 608
REMOVE AND INSTALL INJECTOR ASSEMBLY 610
Removal of injector . 610
Reassembly of injector 611
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY . 613
Remove cylinder head assembly . 614
Install the cylinder head . 617
REMOVE AND INSTALL EGR VALVE ASSEMBLY . 623
Remove the EGR cooler assembly 623
Remove the EGR valve 624
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 625
Removal of Starter Motor 625
Disassembly of Starter Motor 625
Reassembly of Starter Motor . 628
Install the Starter Motor . 629
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 630
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT . 630
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT . 631
REMOVE AND INSTALL ALTERNATOR BELT 632
REMOVE AND INSTALL ALTERNATOR ASSEMBLY 634
Remove the alternator assembly 634
Disassemble the alternator assembly . 635
Reassemble the alternator assembly 636
Install alternator assembly . 636
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY . 637
Removal of fan assembly . 637
Installation of fan assembly 638
REMOVE AND INSTALL RADIATOR AND HYDRAULIC TANK ASSEMBLY . 638
Removal of radiator and hydraulic tank assembly . 638
Installation of radiator and hydraulic tank assembly 641
REMOVE AND INSTALL ENGINE ASSEMBLY 642
Remove engine assembly 642
INSTALLATION OF ENGINE ASSEMBLY . 646
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 647
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY . 648
Removal of engine hood assembly consisting of plastic and steel hood 648
Removal of steel hood . 648
Installation of steel hood 649
Removal of engine hood assembly . 649
Installation of engine hood assembly 650
REMOVE AND INSTALL AFTERTREATMENT DEVICE 651
METHOD FOR REMOVING AFTER TREATMENT DEVICE ASSEMBLY . 652
REMOVE AND INSTALL FUEL TANK ASSEMBLY . 654
Remove the fuel tank 654
Installation of fuel tank . 655
Fuelling fuel tank 655
REMOVE AND INSTALL AIR CLEANER ASSEMBLY . 656
Removal of air cleaner assembly . 656
Installation of air cleaner assembly 657
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 657
Removal of air conditioner compressor assembly 658
Installation of air compressor assembly . 658
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY . 659
Remove air conditioner condenser assembly . 660
Installation of air conditioner condenser assembly 661
POWER TRAIN . 663
PUMP FOR STEERING, WORK EQUIPMENT, COOLING FAN 663
Removal of the pump for steering, work equipment and cooling fan 663
Installation of hydraulic pump assembly . 663
ARTICULATED JOINT ASSEMBLY 664
Removal of articulation joint assembly 664
Installation of articulation joint assembly . 664
HST MOTOR ASSEMBLY 665
Removal of HST motor assembly . 665
Installation of variable motor assembly . 666
HST PUMP ASSEMBLY . 667
Removal of HST pump assembly 667
Installation of variable motor assembly . 667
GEARBOX (TRANSFER ASSEMBLY) . 669
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY 669
SPECIFICATIONS 669
Conversion tables . 670
TORQUE SPECIFICATIONS . 671
Wheel nut tightening torques 672
Maintenance . 673
MANDATORY PROCEDURE . 674
End-stop plier setting 675
Input seal greasing . 676
Maintenance intervals . 677
Lubricant & Sealant specifications 678
SAFETY PRECAUTIONS 679
FLANGED REDUCTION GEAR 315 TYPE: INTEGRAL 315 INPUT GEAR 681
Exploded view . 681
Disassembly . 682
Assembly 685
PLANETARY REDUCTION GEAR 1: 4;23 688
Exploded view . 688
Disassembly . 689
Assembly 693
Special tools . 698
BEVEL PINION FLANGED TO REDUCTOR 700
Exploded view . 700
Disassembly . 701
Assembly 704
Special tools . 708
RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL 711
Exploded view . 711
Install and Adjust 712
INTEGRATED GEAR BOX . 715
Disassembly . 716
Assembly 720
Special Tool 724
REAR AXLE ASSEMBLY 725
Removal of rear axle assembly . 725
Installation of rear axle assembly 727
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS . 728
SAFETY PRECAUTIONS 728
PLANETARY REDUCTION AND AXLE SHAFT 729
Exploded view . 729
Disassembly . 730
Assembly 734
Special Tools . 738
RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL 740
Exploded view . 740
Install and adjust 741
DIFFERENTIAL WITH BLOCK TO SPHERES 100% . 744
Exploded view . 744
Disassembly . 745
Assembly 748
DIFFERENTIAL UNIT 45% . 751
Exploded view . 751
Disassembly . 752
Assembly 754
FRONT AXLE ASSEMBLY . 757
Removal of front axle assembly 757
Installation of front axle assembly . 758
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS . 759
Safety precautions 759
Lubricant & Sealant specifications 759
BRAKE: SERVICE BRAKE, NEGATIVE BRAKE, 100% LOCKED . 761
SAFETY PRECAUTIONS 761
Exploded view . 762
Brake working conditions 763
EMERGENCY RELEASE INSTRUCTIONS 767
Disassembly . 768
Assembly 774
Brake piston gap check 783
Special tools . 784
DISASSEMBLY AND ASSEMBLY OF NORMAL PRELOADED DIFFERENTIAL UNIT 785
SAFETY PRECAUTIONS 785
Exploded view . 786
Disassembly . 787
Assembly 790
PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45% 793
SAFETY PRECAUTIONS 793
Exploded view . 794
Disassembly . 795
Assembly 798
BEVEL PINION: NORMAL FLANGE AND NUT REVOLUTION COUNTER VERSION 801
SAFETY PRECAUTIONS 801
Exploded view . 802
Disassembly . 803
Assembly 806
Assembly: Revolution counter version 811
Special tools . 813
BEVEL PINION 818
SAFETY PRECAUTIONS 818
Exploded view . 819
Disassembly . 820
Assembly 822
Special tools . 826
RING AND PINION ADJUSTING: VERSION PINION COVER AND SINGLE ARM 830
SAFETY PRECAUTIONS 830
Exploded view . 831
Assembly 832
Special tools . 836
RING AND PINION ADJUSTING: VERSION PINION INTEGRAL AND DOUBLE ARM . 837
SAFETY PRECAUTIONS 837
Exploded view . 838
Assembly 839
UNDERCARRIAGE AND FRAME . 842
REMOVAL AND INSTALLATION OF COUNTERWEIGHTASSEMBLY . 842
Removal of counterweight assembly . 842
Installation of counterweight assembly 842
HYDRAULIC SYSTEM 843
REMOVE AND INSTALL LIFT CYLINDER ASSEMBLY . 843
Remove lift cylinder assembly . 843
Removal of lift cylinder assembly . 843
Install lift cylinder assembly 844
REMOVE AND INSTALL DUMP CYLINDER ASSEMBLY . 844
Remove dumb cylinder assembly . 844
Remove dump cylinder assembly . 844
Installation of dump cylinder assembly 845
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY . 845
Remove steering cylinder assembly . 846
Remove steering cylinder assembly . 846
Install steering cylinder assembly 846
WORK EQUIPMENT SYSTEM . 847
REMOVE AND INSTALL MAIN VALVE ASSEMBLY 847
Removal of main control valve assembly 847
Installation of main control valve assembly . 850
Removal of multifunction lever 851
REMOVE AND INSTALL QUICK COUPLER ASSEMBLY . 852
Remove quick coupler assembly . 852
Install quick coupler assembly 853
CAB AND ITS ATTACHMENTS . 854
REMOVE AND INSTALL OPERATOR‘S CAB GLASS (ADHERED GLASS) . 854
Preparation work for replacing the front window pane 855
Preparation work for replacing the rear window pane . 855
Preparation work for replacing the door window pane . 856
Left door assembly 856
Right door assembly . 856
Remove operator’s cab glass (adhered glass) . 856
Install operator’s cab glass (adhered glass) 858
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 860
Remove air conditioner unit assembly 861
Install heater unit assembly 863
REMOVE AND INSTALL OPERATOR‘S SEAT ASSEMBLY . 863
Remove operator‘s seat assembly (STD) . 863
Install operator‘s seat assembly (STD) 864
Remove operator‘s seat assembly (air suspension, heatable) 864
Install operator‘s seat assembly (air suspension, heatable) . 865
REMOVE AND INSTALL SEAT BELT 866
Remove seat belt on STD seat 866
Install seat belt on STD seat . 867
Remove seat belt on suspension, heatable seat . 867
Install seat belt on suspension, heatable seat 868
ELECTRICAL SYSTEM . 869
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY . 869
Method for removing engine controller assembly 870
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 872
Method for removing the cover of the console 872
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY . 873
Method for removing machine monitor assembly 873
Method for installing machine monitor assembly 876
REMOVE AND INSTALL CENTRAL ELECTRIC BOARD (CEB) . 877
Remove the cover of the console . 877
Remove central electric board (CEB) . 878
Remove I/O controller 64P . 878
Remove differential lock relay 878
Install differential lock rely 878
Install I/O controller 64P 879
Install central electric boar (CEB) . 879
Installation of the cover of the console 880
REMOVE AND INSTALL RELAYBOX . 882
Remove relaybox . 882
Remove battery relay 883
Remove the grommet frame from cables 883
Install the battery relay . 884
Install the grommet frame to cables . 884
Install relay box . 885
REMOVE AND INSTALL EPC CONTROLLER ASSEMBLY 886
Method for removing the cover of the console 886
MAINTENANCE STANDARD 887
ABBREVIATION LIST . 889
List of abbreviations used in the text 889
List of abbreviations used in the circuit diagrams 894
ENGINE AND COOLING 895
MAINTENANCE STANDARD OF ENGINE MOUNT 895
MAINTENANCE STANDARD OF DAMPER 896
MAINTENANCE STANDARD OF COOLING FAN MOTOR . 897
POWER TRAIN . 898
MAINTENANCE STANDARD OF TRANSFER 898
MAINTENANCE STANDARD OF REAR AXLE . 899
MAINTENANCE STANDARD OF FRONT AXLE 900
BRAKE SYSTEM 901
MAINTENANCE STANDARD OF PARKING BRAKE . 901
HYDRAULIC SYSTEM 902
CAB AND ITS ATTACHMENTS . 906
Cabin – adjustment 906
APPENDIX 907
ABBREVIATION LIST . 909
List of abbreviations used in the text 909
List of abbreviations used in the circuit diagrams 914
AIR CONDITIONER SYSTEM 915
PRECAUTIONS FOR REFRIGERANT . 915
AIR CONDITIONER COMPONENT . 916
Specifications of air conditioner . 916
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE . 917
OUTLINE OF REFRIGERATION CYCLE 918
Compression (Compressor) 918
Condensation (Condenser) 918
Expansion (Expansion valve) . 918
Evaporation (Evaporator) 919
Relation between refrigerant and cooling trouble 919
AIR CONDITIONER TROUBLESHOOTING CHART . 921
Cooling trouble . 921
Heating trouble . 921
CONNECTION OF SERVICE TOOL 922
METHOD FOR CONNECTING SERVICE TOOL 923
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS . 924
Precautions for disconnection . 924
Precautions for connection 925
HANDLE COMPRESSOR OIL . 926
Management of compressor oil (SANDEN: SP-10 for use with R134a) . 926
Filling of compressor oil . 926
The quantity of compressor oil when the compressor is replaced 927
OTHER . 929
HYDRAULIC CIRCUIT DIAGRAM . 933
WIRING DIAGRAMS . 934
Contents 934
1-0 SYMBOLS SUMMARY, ABBREVIATIONS 935
1-1 HARNESS ARRANGEMENT DETAILS, JOYSTICK BUTTONS . 936
1-2 CAN BUS SUMMARY . 937
2-0 POWER SUPPLY, STARTER SWITCH 938
2-1 GROUNDING . 939
2-2 RELAYB., STARTER, ALTERN., BATTERY, GLOW PLUG . 940
2-3 MAIN ENGINE (EGR) RELAY, EGR VALVE 941
3-0 ECU, DPF SENS., REGENER. SW., SEC. ENG. STOP 942
3-1 ECU, ENGINE SENSORS . 943
3-2 INJECT., FUEL P., AIR CLEAN., TRAVEL PED., OIL PR . 944
4-0 MONITOR, I/O CONTROLLER 64P, BUZZER . 945
4-1 KOMTRAX CTRL, SERVICE CONNECTOR . 946
4-2 FLUID-SENSORS (OIL, FUEL, COOLANT), SPEED SENS 947
5-0 IMMOBILIZER, PARKING BRAKE, FNR SWITCH 948
5-1 HST CONTROLLER, DRIVING FUNCTIONS . 949
5-2 HST CONTROLLER INPUTS, AUTO INCH 950
5-3 CREEP . 951
6-0 FAN DRIVE, REVERSE FAN 952
7-0 AIR CONDITIONER, OPERATOR’S SEAT 953
7-1 WASHER, WIPER, REAR WINDOW HEATER, HORN . 954
8-0 LIGHTING FRONT 955
8-1 FLASHER . 956
8-2 REAR LIGHT, BACKUP AL., REAR FLASHER 957
8-3 WORK LAMPS 958
8-4 INTERIOR LAMP, ROTATING BEACON, PLUG BOX 959
9-0 3RD HYDRAULIC CIRCUIT EPC INPUT . 960
9-1 3RD HYDRAULIC CIRCUIT EPC OUTPUT 961
10-0 ECSS, OVER CENTER VALVE 962
10-1 RETURN TO DIG, QUICK COUPLER . 963
10-2 RADIO, CLS, BLANK OPTION . 964
10-3 COLD AREA KIT (OPT) 965
W1 WIRING HARNESS LIST 1 966
W2 CONNECTOR LIST 1 . 967
W2 CONNECTOR LIST 2 . 968
W2 CONNECTOR LIST 3 . 969
W2 CONNECTOR LIST 4 . 970
W2 CONNECTOR LIST 5 . 971
W3 PIN LOCATION LIST 1 972
W3 PIN LOCATION LIST 2 973
W3 PIN LOCATION LIST 3 974
W3 PIN LOCATION LIST 4 975
W3 PIN LOCATION LIST 5 976
W3 PIN LOCATION LIST 6 977
W3 PIN LOCATION LIST 7 978
W3 PIN LOCATION LIST 8 979
W3 PIN LOCATION LIST 9 980
W3 PIN LOCATION LIST 10 . 981
W3 PIN LOCATION LIST 11 . 982
W3 PIN LOCATION LIST 12 . 983
W3 PIN LOCATION LIST 13 . 984
W3 PIN LOCATION LIST 14 . 985
W3 PIN LOCATION LIST 15 . 986
W3 PIN LOCATION LIST 16 . 987
W3 PIN LOCATION LIST 17 . 988
W3 PIN LOCATION LIST 18 . 989
W3 PIN LOCATION LIST 19 . 990
W3 PIN LOCATION LIST 20 . 991
W3 PIN LOCATION LIST 21 . 992
W3 PIN LOCATION LIST 22 . 993
W3 PIN LOCATION LIST 23 . 994
W3 PIN LOCATION LIST 24 . 995
W3 PIN LOCATION LIST 25 . 996
W3 PIN LOCATION LIST 26 . 997
W3 PIN LOCATION LIST 27 . 998
W3 PIN LOCATION LIST 28 . 999
W3 PIN LOCATION LIST 29 .1000
W4 PARTS LIST 1 .1001
W4 PARTS LIST 2 .1002
W4 PARTS LIST 3 .1003
Connector diagram 1 .1005
Connector diagram 2 .1006
Connector diagram 3 .1007
Connector table for the operator‘s cab wiring harness (Part 1/2) 1007
Connector diagram 4 .1008
Connector table for operator‘s cab wiring harness (Part 2/2) 1008
Connector diagram 5 .1009

DESCRIPTION:

Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09002 – PDF DOWNLOAD

           Model:                    Serial number:

• WA70M-8E0          H71511 and up

G.B 30/12/24