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Komatsu WA100-1 Wheel Loader Shop Manual SEBM04160105 – PDF DOWNLOAD
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Description
Komatsu WA100-1 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA100-1 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA100-1
Serial Number: 10001 and up
Book Code: SEBM04160105
Language: English
Pages: 626
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA100-1 Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
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 ADJUSTING:
This section 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.
DISASSEMBLY AND ASSEMBLY:
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.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA100-1 Wheel Loader Shop Manual
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
KOMATSU WA100-1 WHEEL LOADER SHOP MANUAL SEBM04160105 – PDF DOWNLOAD:
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