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Komatsu WA70-1 Shop Manual SEBM04150104 – PDF DOWNLOAD
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Description
Komatsu WA70-1 Shop Manual SEBM04150104 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WA70-1 Shop Manual SEBM04150104 – PDF DOWNLOAD
Language : English
Pages : 498
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu WA70-1 Shop Manual SEBM04150104 – PDF DOWNLOAD
COVER.................................................................................................... 1 CONTENTS................................................................................................. 2 10 ENGINE................................................................................................ 13 12 TESTING AND ADJUSTING............................................................................. 13 STANDARD VALUE TABLE............................................................................. 14 TOOL LIST FOR TESTING AND ADJUSTING.............................................................. 15 ADJUSTING VALVE CLEARANCE........................................................................ 16 MEASURING COMPRESSION PRESSURE................................................................... 17 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................... 18 ADJUSTING FUEL INJECTION TIMING.................................................................. 19 TESTING AND ADJUSTING FAN BELT TENSION........................................................... 20 TESTING AND ADJUSTING FAN BELT TENSION........................................................... 20 ADJUSTING OF FUEL CUT SOLENOID................................................................... 21 MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL............................... 22 13 DISASSEMBLY AND ASSEMBLY.......................................................................... 25 STARTING MOTOR................................................................................... 26 REMOVAL...................................................................................... 26 INSTALLATION................................................................................. 26 ALTERNATOR....................................................................................... 27 REMOVAL...................................................................................... 27 INSTALLATION................................................................................. 27 FUEL INJECTION PUMP.............................................................................. 28 REMOVAL...................................................................................... 28 INSTALLATION................................................................................. 30 NOZZLE HOLDER.................................................................................... 33 REMOVAL...................................................................................... 33 INSTALLATION................................................................................. 33 WATER PUMP....................................................................................... 34 REMOVAL...................................................................................... 34 INSTALLATION................................................................................. 35 CYLINDER HEAD.................................................................................... 36 REMOVAL...................................................................................... 36 INSTALLATION................................................................................. 40 RADIATOR......................................................................................... 44 REMOVAL...................................................................................... 44 INSTALLATION................................................................................. 46 ENGINE........................................................................................... 49 REMOVAL...................................................................................... 49 INSTALLATION................................................................................. 55 FUEL TANK........................................................................................ 61 REMOVAL...................................................................................... 61 INSTALLATION................................................................................. 62 20 POWER TRAIN........................................................................................... 63 21 STRUCTURE AND FUNCTION............................................................................ 63 GENERAL.......................................................................................... 64 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................ 66 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.................................................... 67 TORQUE CONVERTER AND TRANSMISSION PIPING......................................................... 69 TORQUE CONVERTER OIL FILTER...................................................................... 71 TORQUE CONVERTER................................................................................. 72 TORQUE CONVERTER OIL OUTLET VALVE............................................................ 74 TORQFLOW TRANSMISSION............................................................................ 75 TRANSMISSION CONTROL VALVE....................................................................... 82 MAIN REGULATOR VALVE......................................................................... 86 QUICK RETURN VALVE AND ACCUMULATOR........................................................... 87 POWER MODULATING FUNCTION.................................................................... 89 ACTION OF THE CLUTCH CUT-OFF VALVE........................................................... 93 ACCUMULATOR VALVE............................................................................ 95 FORWARD 1ST.................................................................................. 96 TRANSMISSION CONTROL LINKAGE..................................................................... 98 DRIVE SHAFT......................................................................................100 AXLE.............................................................................................101 DIFFERENTIAL.....................................................................................103 FINAL DRIVE......................................................................................106 AXLE MOUNT.......................................................................................107 TIRE AND WHEEL...................................................................................111 22 TESTING AND ADJUSTING.............................................................................112 STANDARD VALUE TABLE.............................................................................113 TOOL LIST FOR TESTING AND ADJUSTING..............................................................114 MEASURING ENGINE STALL SPEED.....................................................................115 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION......................................117 MEASURING SHIFT LEVER............................................................................119 MEASURING VALVE SPOOL OPERATING FORCE AND TRAVEL.................................................120 TROUBLESHOOTING..................................................................................121 PRECAUTIONS WHEN TROUBLESHOOTING.............................................................122 METHOD OF READING TROUBLESHOOTING TABLE......................................................124 PREVENTING RECURRENCE OF TROUBLE.............................................................126 TROUBLESHOOTING TABLE........................................................................127 1. MACHINE DOES NOT MOVE OFF.............................................................127 2. MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF..........................129 3. LARGE SHOCK WHEN MOVING OFF OR CHANGING GEAR..........................................131 4. LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR.......................................132 5. OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH...........................................133 23 DISASSEMBLY AND ASSEMBLY..........................................................................134 TORQUE CONVERTER, TRANSMISSION...................................................................135 REMOVAL......................................................................................135 INSTALLATION.................................................................................140 TORQUE CONVERTER.................................................................................146 DISASSEMBLY..................................................................................146 ASSEMBLY.....................................................................................148 TRANSMISSION.....................................................................................151 DISASSEMBLY..................................................................................151 ASSEMBLY.....................................................................................158 CLUTCH PACK......................................................................................167 DISASSEMBLY..................................................................................167 ASSEMBLY.....................................................................................173 TRANSMISSION VALVE...............................................................................183 REMOVAL......................................................................................183 INSTALLATION.................................................................................186 TRANSMISSION CONTROL VALVE.......................................................................189 DISASSEMBLY..................................................................................189 ASSEMBLY.....................................................................................193 DRIVE SHAFT......................................................................................198 DISASSEMBLY..................................................................................198 ASSEMBLY.....................................................................................200 FRONT AXLE.......................................................................................202 REMOVAL......................................................................................202 INSTALLATION.................................................................................204 REAR AXLE........................................................................................206 REMOVAL......................................................................................206 INSTALLATION.................................................................................209 DIFFERENTIAL.....................................................................................213 DISASSEMBLY..................................................................................213 ASSEMBLY.....................................................................................216 AXLE HOUSING.....................................................................................228 DISASSEMBLY..................................................................................228 ASSEMBLY.....................................................................................232 24 MAINTENANCE STANDARD..............................................................................241 TRANSMISSION AND ENGINE MOUNT....................................................................242 TORQUE CONVERTER.................................................................................243 TRANSMISSION (1/2) (SERIAL NO. 10001-11999)......................................................244 TRANSMISSION (2/2) (SERIAL NO. 10001-11999)......................................................245 TRANSMISSION CLUTCH ASSEMBLY (SERIAL NO. 10001-11999)............................................247 TRANSMISSION (1/3) (SERIAL NO. 12001AND UP)......................................................249 TRANSMISSION (2/3) (SERIAL NO. 12001AND UP)......................................................250 TRANSMISSION (3/3) (SERIAL NO. 12001AND UP)......................................................252 TRANSMISSION CONTROL VALVE.......................................................................254 DIFFERENTIAL (1/2)...............................................................................258 DIFFERENTIAL (2/2)...............................................................................262 DRIVE SHAFT......................................................................................266 FINAL DRIVE......................................................................................267 AXLE MOUNT.......................................................................................269 40 STEERING SYSTEM.......................................................................................271 41 STRUCTURE AND FUNCTION............................................................................271 HYDRAULIC CIRCUIT FOR STEERING...................................................................272 HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...........................................................274 FLOW DIVIDER VALVE...............................................................................275 STEERING VALVE...................................................................................277 STEERING CYLINDER................................................................................286 CENTER HINGE PIN.................................................................................287 42 TESTING AND ADJUSTING.............................................................................288 STANDARD VALUE TABLE.............................................................................289 TOOL LIST FOR TESTING AND ADJUSTING..............................................................289 MEASURING STEERING WHEEL PLAY....................................................................290 MEASURING OPERATING FORCE OF STEERING WHEEL......................................................291 MEASURING OPERATING TIME OF STEERING WHEEL.......................................................292 MEASURING STEERING OIL PRESSURE..................................................................293 TROUBLESHOOTING..................................................................................294 TROUBLESHOOTING TABLE........................................................................295 1. STEERING WHEEL DOES NOT TURN..........................................................295 2. STEERING WHEEL IS SLUGGISH............................................................296 3. STEERING WHEEL MOVE UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.........................297 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING............297 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT............................................297 43 DISASSEMBLY AND ASSEMBLY..........................................................................298 FLOW DIVIDER VALVE...............................................................................299 REMOVAL......................................................................................299 INSTALLATION.................................................................................300 DISASSEMBLY..................................................................................301 ASSEMBLY.....................................................................................301 STEERING VALVE...................................................................................302 REMOVAL......................................................................................302 INSTALLATION.................................................................................303 STEERING CYLINDER................................................................................304 REMOVAL......................................................................................304 INSTALLATION.................................................................................305 DISASSEMBLY..................................................................................306 ASSEMBLY.....................................................................................308 CENTER HINGE PIN.................................................................................311 REMOVAL......................................................................................311 INSTALLATION.................................................................................315 44 MAINTENANCE STANDARD..............................................................................321 STEERING COLUMN..................................................................................322 FLOW DIVIDER VALVE...............................................................................323 STEERING CYLINDER MOUNT..........................................................................324 STEERING CYLINDER................................................................................325 CENTER HINGE PIN.................................................................................326 50 BRAKE SYSTEM..........................................................................................328 51 STRUCTURE AND FUNCTION............................................................................328 BRAKE PIPING.....................................................................................329 BRAKE MASTER CYLINDER............................................................................331 WHEEL BRAKE......................................................................................333 PARKING BRAKE....................................................................................336 BRAKE CALIPER................................................................................338 52 TESTING AND ADJUSTING.............................................................................339 STANDARD VALUE TABLE.............................................................................340 TOOL LIST FOR TESTING AND ADJUSTING..............................................................341 MEASURING BRAKE PEDAL............................................................................342 TESTING AND ADJUSTING OF BRAKE PEDAL LINKAGE.....................................................343 TESTING BRAKE PERFORMANCE........................................................................346 MEASURING BRAKE OIL PRESSURE.....................................................................347 MEASURING WEAR OF BRAKE DISC.....................................................................348 AIR BLEEDING FROM BRAKE CIRCUIT..................................................................349 TESTING PARKING BRAKE PERFORMANCE................................................................350 CHECKING AND ADJUSTING PARKING BRAKE.............................................................351 MEASURING CLEARANCE OF PARKING BRAKE.............................................................353 TROUBLESHOOTING..................................................................................354 TROUBLESHOOTING TABLE........................................................................355 1. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE............................................355 2. BRAKE CANNOT BE RELEASED OR DRAGS.....................................................356 53 DISASSEMBLY AND ASSEMBLY..........................................................................357 MASTER CYLINDER..................................................................................358 REMOVAL......................................................................................358 INSTALLATION.................................................................................359 DISASSEMBLY..................................................................................360 ASSEMBLY.....................................................................................361 PARKING BRAKE....................................................................................362 REMOVAL......................................................................................362 INSTALLATION.................................................................................364 PARKING BRAKE PAD................................................................................366 REMOVAL......................................................................................366 INSTALLATION.................................................................................367 54 MAINTENANCE STANDARD..............................................................................368 BRAKE MASTER CYLINDER............................................................................369 WHEEL BRAKE......................................................................................370 PARKING BRAKE....................................................................................372 60 WORK EQUIPMENT SYSTEM.................................................................................373 61 STRUCTURE AND FUNCTION............................................................................373 GENERAL..........................................................................................374 HYDRAULIC CIRCUIT................................................................................377 HYDRAULIC CIRCUIT DIAGRAM........................................................................379 HYDRAULIC TANK...................................................................................381 OIL FILTER...................................................................................383 BREATHER.....................................................................................383 MAIN CONTROL VALVE...............................................................................384 RELIEF VALVE.................................................................................388 SAFETY VALVE.................................................................................389 SUCTION VALVE................................................................................390 WORK EQUIPMENT LEVER LINKAGE.....................................................................399 HYDRAULIC PUMP...................................................................................401 HYDRAULIC CYLINDER...............................................................................402 BUCKET LINKAGE...................................................................................403 BUCKET POSITIONER................................................................................405 62 TESTING AND ADJUSTING.............................................................................407 STANDARD VALUE TABLE.............................................................................408 TOOL LIST FOR TESTING AND ADJUSTING..............................................................409 MEASURING DUMP AND LIFT CONTROL LEVERS...........................................................410 ADJUSTING DUMP AND LIFT CONTROL LEVERS...........................................................411 MEASURING DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL...............................................414 MEASURING HYDRAULIC PRESSURE.....................................................................415 MEASURING LIFT ARM AND BUCKET....................................................................417 MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET.................................................418 ADJUSTING BUCKET POSITIONER......................................................................419 TROUBLESHOOTING..................................................................................421 TROUBLESHOOTING TABLE........................................................................422 1. LIFT ARM DOES NOT RISE................................................................422 2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER.......................423 3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT......................424 4. BUCKET CANNOT BE HOLD DOWN WITH LIFT ARM CYLINDER.....................................424 5. LIFT HAS LARGE HYDRAULIC DRIFT........................................................424 6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK.............................................424 7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"....424 8. BUCKET DOES NOT TILT BACK.............................................................425 9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...............................426 10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK........................................427 11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER....................................427 12. BUCKET HAS LARGE HYDRAULIC DRIFT.....................................................427 13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD..............................427 14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"....427 15. CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY....................428 63 DISASSEMBLY AND ASSEMBLY..........................................................................429 HYDRAULIC TANK...................................................................................430 REMOVAL......................................................................................430 INSTALLATION.................................................................................432 HYDRAULIC PUMP...................................................................................434 REMOVAL......................................................................................434 INSTALLATION.................................................................................436 MAIN CONTROL VALVE...............................................................................439 REMOVAL......................................................................................439 INSTALLATION.................................................................................441 DISASSEMBLY (SERIAL NO. 10001-11999).........................................................443 ASSEMBLY (SERIAL NO. 10001-11999)............................................................446 DISASSEMBLY (SERIAL NO. 12001AND UP).........................................................449 ASSEMBLY (SERIAL NO. 12001 AND UP)...........................................................452 DUMP CYLINDER....................................................................................455 REMOVAL......................................................................................455 INSTALLATION.................................................................................456 LIFT CYLINDER....................................................................................457 REMOVAL......................................................................................457 INSTALLATION.................................................................................458 LIFT AND DUMP CYLINDER...........................................................................459 DISASSEMBLY..................................................................................459 ASSEMBLY.....................................................................................461 WORK EQUIPMENT...................................................................................464 REMOVAL......................................................................................464 INSTALLATION.................................................................................467 COUNTERWEIGHT....................................................................................470 REMOVAL......................................................................................470 INSTALLATION.................................................................................470 64 MAINTENANCE STANDARD..............................................................................471 MAIN CONTROL VALVE...............................................................................472 HYDRAULIC PUMP...................................................................................475 LIFT CYLINDER....................................................................................476 DUMP CYLINDER....................................................................................477 BUCKET LINKAGE...................................................................................478 BUCKET POSITIONER................................................................................482 BUCKET...........................................................................................483 80 ELECTRICAL SYSTEM.....................................................................................484 81 STRUCTURE AND FUNCTION............................................................................484 CLUSTER GAUGE....................................................................................485 ELECTRIC WIRING DIAGRAM..........................................................................487 ELECTRIC WIRING CIRCUIT DIAGRAM..................................................................489 ENGINE STARTING CIRCUIT..........................................................................491 ENGINE STOP CIRCUIT..............................................................................491 PREHEATING CIRCUIT...............................................................................493 PREHEATING WITH STARTING SWITCH..............................................................493 PROXIMITY SWITCH.................................................................................495 83 DISASSEMBLY AND ASSEMBLY..........................................................................496 INSTRUMENT PANEL.................................................................................497 REMOVAL......................................................................................497 INSTALLATION.................................................................................498
DESCRIPTION:
Komatsu WA70-1 Shop Manual SEBM04150104 – PDF DOWNLOAD
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.
S.S 12/12/24
