KOMATSU BACKHOE LOADER WB97R-5E0 SERVICE REPAIR MANUAL – PDF Download

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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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