Komatsu WA700-1 Wheel Loader Shop Manual SEBM009501 PDF DOWNLOAD

Description

Komatsu WA700-1 Wheel Loader Shop Manual SEBM009501 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA700-1 Wheel Loader Shop Manual SEBM009501 – PDF DOWNLOAD

Language : English
Pages : 880
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA700-1 Wheel Loader Shop Manual SEBM009501 – PDF DOWNLOAD

• SERIAL NUMBERS VVA700-1 – 15001 and up

MAIN MENU . 0
SAFETY 7
FOREWORD 9
GENERAL . 9
HOW TO READ THE SHOP MANUAL . 10
HOISTING INSTRUCTIONS . 11
COATING MATERIALS . 12
STANDARD TIGHTENING TORQUE 14
ELECTRIC WIRE CODE 17
CONVERSION TABLE . 18
01 GENERAL 25
GENERAL ASSEMBLY DRAWING . 26
SPECIFICATIONS 27
WEIGHT TABLE . 30
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION . 35
POWER TRAIN 38
RADIATOR AND COOLER 40
DAMPER . 41
HYDRAULIC CIRCUIT FOR POWER TRAIN 42
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 43
TORQUE CONVERTER AND TRANSMISSION PIPING . 44
TORQUE CONVERTER AND PTO . 45
TORQUE CONVERTER REGULATOR VALVE . 48
TORQUE CONVERTER OIL COOLER 49
TRANSMISSION . 50
TRANSMISSION CONTROL VALVE . 55
TRANSMISSION SOLENOID VALVE 58
TORQUE CONVERTER RELIEF VALVE 66
LUBRICATION BYPASS VALVE . 67
TRANSMISSION SOLENOID VALVE 68
EMERGENCY MANUAL SPOOL . 69
TRANSMISSION OIL FILTER 70
PILOT OIL FILTER . 71
TRANSFER . 72
DRIVE SHAFT 73
CENTER SUPPORT . 74
AXLE . 75
DIFFERENTIAL . 77
FINAL DRIVE 80
AXLE MOUNT . 82
CENTER HINGE PIN . 84
FLOOR SUPPORT 85
STEERING PIPING DIAGRAM 86
STEERING CIRCUIT DIAGRAM . 87
STEERING COLUMN AND LINKAGE 88
STEERING GEAR BOX 89
STEERING AND SWITCH PUMP . 90
STEERING VALVE . 92
ROTARY SEAL 94
SLOW RETURN VALVE 102
DIVERTER VALVE .103
EMERGENCY STEERING RELIEF VALVE 104
BRAKE AND AIR PIPING .108
BRAKE AND AIR CIRCUIT DIAGRAM .110
AIR GOVERNOR 111
AIR TANK .113
SAFETY VALVE .113
BRAKE VALVE 114
RELAY VALVE 118
DOUBLE CHECK VALVE .119
BRAKE CHAMBER 120
SLACK ADJUSTER .122
CHECK VALVE 125
HYDRAULIC TANK PRESSURIZING VALVE 126
PARKING BRAKE SOLENOID VALVE .127
SPRING CYLINDER .128
BRAKE .129
PARKING BRAKE .130
HYDRAULIC PIPING .132
HYDRAULIC CIRCUIT SYSTEM 134
HYDRAULIC CIRCUIT DIAGRAM .135
WORK EQUIPMENT LEVER LINKAGE .136
HYDRAULIC TANK 137
ACCUMULATOR 139
MAIN PUMP 141
PPC VALVE 153
PRESSURE DIFFERENTIAL VALVE .158
MAIN CONTROL VALVE .160
HYDRAULIC LEVER OPERATION 167
LUBRICATION OF WORK EQUIPMENT 174
BUCKET LINKAGE .176
BUCKET POSITIONER AND BOOM KICK-OUT 178
CAB .180
AIR CONDITIONER 181
ELECTRICAL WIRING DIAGRAM CIRCUIT .187
ELECTRICAL WIRING DIAGRAM CIRCUIT .186
ENGINE CONTROL SYSTEM 189
ENGINE CONTROLLER .190
ELECTRICAL VEHICLE MONITORING SYSTEM (EVMS) 191
SENSORS .197
ENGINE STARTING CIRCUIT .204
ENGINE STOP CIRCUIT 205
AUTO PRIMING SYSTEM (APS) 206
COMBINATION SWITCH .211
ELECTRICAL TRANSMISSION CONTROL 212
ELECTRICAL PARKING BRAKE CONTROL .216
ELECTRICAL PARKING BRAKE 217
KICK-DOWN SWITCH .225
20 TESTING AND ADJUSTING 231
STANDARD VALUE TABLE FOR ENGINE 233
STANDARD VALUE TABLE FOR CHASSIS .234
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 237
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (ENGINE) .241
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (CHASSIS) .242
ADJUSTING VALVE CLEARANCE 243
MEASURING COMPRESSION PRESSURE 244
MEASURING BLOW-BY PRESSURE 245
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE .246
TESTING AND ADJUSTING FUEL INJECTION TIMING 247
MEASURING EXHAUST GAS COLOR .249
TESTING AND ADJUSTING ALTERNATOR BELT TENSION .250
ADJUSTING ENGINE SPEED SENSOR .251
MEASURING OPERATING EFFORT OF ACCELERATOR PEDAL .252
ADJUSTING POTENTIOMETER, TRAVEL OF ACCELERATOR PEDAL 253
MEASURING SHIFT LEVER .255
MEASURING STALL SPEED .256
MEASURING HYDRAULIC PRESSURE (TORQUE CONVERTOR, TRANSMISSION PRESSURE) 258
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL 260
MEASURING WHEEL LOCK RING CLEARANCE .261
MEASURING STEERING WHEEL PLAY .262
MEASURING OPERATING FORCE AND OPERATING TIME OF STEERING WHEEL 263
TESTING AND ADJUSTING STEERING LINKAGE 264
MEASURING STEERING OIL PRESSURE 266
MEASURING EMERGENCY STEERING PRESSURE 267
MEASURING BRAKE PEDAL .269
MEASURING AIR PRESSURE 270
TESTING BRAKE PERFORMANCE 272
CHECKING BRAKE PISTON LEAKAGE .273
MEASURING WEAR OF BRAKE DISC .274
AIR BLEEDING FROM BRAKE LINE .275
TESTING PARKING BRAKE PERFORMANCE 276
CHECKING AND ADJUSTING PARKING BRAKE 277
MEASURING DUMP AND LIFT CONTROL LEVERS .279
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT .281
AIR BLEEDING FROM PISTON PUMP 284
MEASURING WORK EQUIPMENT .285
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT 286
ADJUSTING BUCKET POSITIONER 287
ADJUSTING BOOM KICK-OUT 288
ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE) .289
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR 290
TROUBLESHOOTING .292
ELECTRICAL CIRCUIT FOR ENGINE, TRANSMISSION AND PARKING BRAKE .293
ELECTRICAL CIRCUIT SYSTEM .297
VEHICLE MONITOR SYSTEM 298
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 299
LOCATION OF CONNECTORS 301
CONNECTOR TERMINAL NUMBERS 302
POINTS TO REMEMBER WHEN TROUBLESHOOTING 308
SEQUENCE OF EVENTS IN TROUBLESHOOTING 309
PRECAUTIONS WHEN CARRYING OUT 310
HANDLING CONNECTORS 317
CHECK BEFORE TROUBLESHOOTING 318
JUDGEMENT ON POWER TRAIN .319
METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES 321
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (ENGINE, TRANSMISSION, PARKING BRAKE) .326
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER .327
TROUBLESHOOTING OF APS 329
E-1: ENGINE DOES NOT START 331
a) Inspection of starting circuit .331
b) Inspection of battery – battery relay – starting switch 331
c) Check starting switch – governor cut relay .332
E-2: ENGINE DOES NOT STOP .333
E-3: ENGINE STOPS WHEN TRAVELING 333
E-4: PARKING BRAKE DOES NOT WORK 334
a) If parking brake does not work when parking brake switch is ON (applied) .334
b) If parking brake does not work then air pressure has dropped (does not work as emergency brake) 334
E-5: PARKING BRAKE IS NOT RELEASED 335
E-6: PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 337
E-7: WHEN PARKING BRAKE IS APPLIED, TRANSMISSION DOES NOT ENTER NEUTRAL (PARKING BRAKE IS WORKNG NORMALLY) 337
E-8: TRANSMISSION DOES NOT WORK NORMALLY 338
a) Problem in parking brake, transmission cut-off switch, neutral relay circuit .339
b) Defective continuity in FORWARD solenoid circuit .341
c) Defective continuity in REVERSE solenoid circuit .343
d) Contact in F-R circuit .345
e) Problem in speed solenoid circuit 349
f) Contact in speed circuit .353
E-9: KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1 – F4 SWITCHES CORRECTLY) .359
E-10: KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOWS NOT CARRY OUT SELF-HOLD OPERATION) 362
E-11: KICK-DOWN OPERATION IS NOT CANCELED .363
E-12: KICK-DOWN WORKS MISTAKE WHEN TRAVELING IN F2 365
E-13: MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED 365
E-14: PREHEATING IS NOT CARRIED OUT .367
a) Does not carry out preheating automatically 368
b) Does not carry out preheating either manually or automatically .368
E-15: PREHEATING STAYS ON .369
a) Automatic preheating is not canceld 369
b) Preheating is carried out even when heater switch is turned OFF 369
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM 370
M-1 Brake oil level flashes when engine is stopped 372
M-2 Engine oil level flashes when engine is stopped .372
M-3 Radiator water level flashes when engine is stopped .373
M-4 Battery charge flashes when engine is running .373
M-5 Transmission oil filter clogging flashes when engine is running .375
M-6 Fuel level flashes when engine is running .377
M-7 Brake line failure flashes when engine is running .377
M-8 Engine oil pressure flashes when engine is running 379
M-9 Radiator water level flashes when engine is running .379
M-10 Drop in air pressure flashes when engine is running 381
M-11 Engine water temperature flashes when engine is running 381
M-12 Torque converter oil temperature flashes when engine is running 381
M-13 Parking brake lights up abnormally, or does not light up .383
a) If parking brake stays lighted up 383
b) If parking brake does not light up .383
M-14 Working lamp lights up abnormally, or does not light up 385
a) If working lamp stays lighted up .385
b) If working lamp does not light up 385
M-15 Preheating lights up, or does not light up .387
a) Preheating lights up .387
b) Preheating does not light up .387
M-16 Main steering failure lights up, or does not light up 389
a) Main steering failure lights up 389
b) Main steering failure does not light up 389
M-17 Transmission cut-off lights up, does not light up 391
a) Transmission cut-off lights up .391
b) Transmission cut-off does not light up .391
M-18 Turn signal and Hi beam light up, or do not light up .393
a) Turn signal (right) pilot display lights up 393
b) Turn signal (left) pilot display lights up .394
c) Turn signal (right) pilot display does not light up 395
d) Turn signal (left) pilot display does not light up .395
e) Hi beam pilot does not light up 396
f) Hi beam pilot stays lighted up .396
M-19 Turn signal does not flash even when hazard switch is turned on 398
M-20 Speedometer display does not work normally .399
M-21 Hourmeter does not work normally .400
M-22 When starting switch is turned on, monitor panel does not work, or only part lights up .401
a) None of monitor panel lights up 401
b) Except for speedometer module, none of monitor panel lights up .401
c) None of CAUTION items light up .402
d) Some other parts do not light up .402
M-23 When starting switch is turned ON, all monitor panel lights up, but does not go out 402
M-24 Engine oil pressure flashes or Battery charge flashes when engine is stopped .403
a) Engine oil pressure flashes, and alarm buzzer and warning lamp are actuated 403
b) Battery charge flashes, and warning lamp lights up .403
M-25 None of machine monitor panel lighting lights up, or part does not light up 405
a) Even when combination lamp is placed at SMALL, none of panel lighting lights up 405
b) Even when working lamp is switched ON, none of monitor panel lights up .407
c) Even when starting switch is turned ON, none of monitor panel lights up 409
d) Part of panel does not light up 409
M-26 When starting switch is turned to ON position (engine stopped), buzzer does not sound for 1 sec 411
M-27 No abnormality is shown on monitor display, but alarm buzzer sounds 411
M-28 When starting switch is turned to ON position (engine stopped), warning lamp does not light up for 2 sec .413
M-29 No abnormality is shown on monitor display, but warning lamp lights up .414
M-30 Abnormality in Fuel guage system .415
a) If nothing is displayed in display area 415
b) If indicator remains at FULL .415
M-31 Abnormality in Air pressure guage system .417
a) If nothing is displayed in display area 417
b) If indicator remains at maximum level 417
M-32 Abnormality in Engine water temperature guage system .419
a) If nothing is displayed in display area 419
b) If indicator remains at minimum level 419
M-33 Abnormality in Torque converter oil temperature guage system .421
a) If nothing is displayed in display area 421
b) If indicator remains at minimum level 421
TROUBLESHOOTING CHART FOR POWER TRAIN, STEERING, AIR AND BRAKE, WORK EQUIPMENT (MECHANICAL SYSTEM) 424
POWER TRAIN .425
1. Machine does not move 425
2. Machine lacks power or speed .427
3. Excessive time lag when starting machine or shifting gear 428
4. Torque converter oil temperature too high 429
STEERING SYSTEM .430
1. Steering wheel does not turn .430
2. Steering wheel is sluggish .431
3. Steering wheel moves unsteadily or is subjected to large shock .432
4. Machine tends to turn naturally in one particular direction when traveling .432
5. Left and right turning radii are different .432
AIR AND BRAKE SYSTEM 433
1. Air pressure does not rise at all 433
2. Air pressure does not rise to the specified range 434
3. Brake is ineffective or not very effective .435
4. Brake does not release, or drags .436
5. Parking brake does not release, or drags .437
WORK EQUIPMENT 438
1. Lift arm does not rise .438
2. Lift arm moves slowly or does not have sufficient lifting power 439
3. Lift arm movement becomes slow after it reaches a certain height .440
4. Bucket cannot be held down with lift arm cylinder 440
5. Lift arm has large hydraulic drift .440
6. Lift arm movement is unsteady during work 440
7. Lift arm lowers momentarily when control lever is shifted from “Hold” to “Raise” .440
8. Bucket does not tilt back 441
9. Bucket moves slowly or has insufficient tilt back power 442
10. Bucket movement becomes slow during tilt back .443
11. Bucket cannot be held down by the bucket cylinder .443
12. Bucket has large hydraulic drift 443
13. Bucket moves unsteadily when machine travels under load (Main control valve in “Hold”) 443
14. Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back” .443
15. Control levers of lift arm and dump move stiffly and sluggishly .444
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR) 446
Judgement table for engine controller and engine related parts 448
R-1 Abnormality in power source .449
R-2 Abnormality in controller .450
R-3 Abnormality in rack sensor system .451
R-4 Abnormality in governor solenoid system .452
R-5 Abnormality in governor cut relay system 453
R-6 Abnormality in pre-stroke solenoid system .454
R-7 Abnormality in rack sensor power source system 455
R-8 a. Abnormality in engine speed sensor system A 456
b. Abnormality in engine speed sensor system B 457
R-9 Abnormality in acceleration sensor system .458
R-10 Abnormality in governor servo system .460
R-11 Abnormality in engine water temperature system .461
R-12 Engine does not start 462
Electric circuit diagram of engine controller system 464
30 DISASSEMBLY AND ASSEMBLY .465
STARTING MOTOR 468
REMOVAL AND INSTALLATION .468
ALTERNATOR 469
REMOVAL AND INSTALLATION 469
ALTERNATOR CORE 470
REMOVAL .470
INSTALLATION 473
TURBOCHARGER (TOP) .475
REMOVAL AND INSTALLATION 475
FUEL INJECTION PUMP .476
REMOVAL AND INSTALLATION 476
TURBOCHARGER (BOTTOM) 478
REMOVAL AND INSTALLATION 478
NOZZLE HOLDER .479
REMOVAL AND INSTALLATION 479
OIL COOLER 480
REMOVAL AND INSTALLATION .480
THERMOSTAT 481
REMOVAL AND INSTALLATION .481
WATER PUMP 482
REMOVAL AND INSTALLATION 482
CYLINDER HEAD .483
REMOVAL .483
INSTALLATION 485
AIR COMPRESSOR 489
REMOVAL AND INSTALLATION 489
RADIATOR .490
REMOVAL .490
INSTALLATION 494
ENGINE 498
REMOVAL .498
INSTALLATION 505
DAMPER 513
REMOVAL .513
INSTALLATION 517
DISASSEMBLY .522
ASSEMBLY 524
TORQUE CONVERTER CHARGING AND PPC PUMP 528
REMOVAL .528
INSTALLATION 530
TORQUE CONVERTER, PTO, TRANSMISSION .532
REMOVAL .532
INSTALLATION 542
TORQUE CONVERTER 552
DISASSEMBLY .552
ASSEMBLY 556
PTO .561
DISASSEMBLY .561
ASSEMBLY 563
TRANSMISSION 566
DISASSEMBLY .566
ASSEMBLY 578
TRANSFER 592
DISASSEMBLY .592
ASSEMBLY 599
TRANSMISSION VALVE 609
REMOVAL .609
INSTALLATION 610
DISASEMBLY AND ASSEMBLY .612
CENTER SUPPORT 617
REMOVAL .617
INSTALLATION 618
DISASSEMBLY .620
ASSEMBLY 622
DRIVE SHAFT .625
DISASSEMBLY .625
ASSEMBLY 627
FRONT AXLE 628
REMOVAL .628
INSTALLATION 630
REAR AXLE .632
REMOVAL .632
INSTALLATION 637
DIFFERENTIAL 642
REMOVAL .642
INSTALLATION 645
DISASSEMBLY .647
ASSEMBLY 651
FINAL DRIVE .660
DISASSEMBLY .660
ASSEMBLY 664
STEERING GEAR .668
REMOVAL .668
INSTALLATION 669
DISASSEMBLY .670
ASSEMBLY 671
STEERING, SWITCH PUMP .674
REMOVAL .674
INSTALLATION 675
STEERING VALVE 676
REMOVAL .676
INSTALLATION 678
DISASSEMBLY AND ASSEMBLY 680
DIVERTER VALVE 682
DISASSEMBLY AND ASSEMBLY 682
STEERING CYLINDER .684
REMOVAL .684
INSTALLATION 686
BRAKE VALVE .689
REMOVAL .689
INSTALLATION 691
DISASSEMBLY .693
ASSEMBLY 695
BRAKE CHAMBER .697
REMOVAL .697
INSTALLATION 698
DISASSEMBLY .699
ASSEMBLY 702
AIR GOVERNOR 705
DISASSEMBLY .705
ASSEMBLY 706
SLACK ADJUSTER 707
REMOVAL .707
INSTALLATION 708
DISASSEMBLY .709
ASSEMBLY 710
BRAKE .711
REMOVAL .711
INSTALLATION 713
DISASSEMBLY .715
ASSEMBLY 719
SPRING CYLINDER .725
REMOVAL .725
INSTALLATION 726
DISASSEMBLY .727
ASSEMBLY 728
PARKING BRAKE .729
REMOVAL .729
INSTALLATION 730
DIASSEMBLY AND ASSEMBLY .731
PARKING BRAKE PAD .732
REMOVAL AND INSTALLATION 732
HYDRAULIC TANK 733
REMOVAL .733
INSTALLATION 735
HYDRAULIC PUMP 737
REMOVAL .737
INSTALLATION 738
PISTON PUMP .739
DISASSEMBLY .739
ASSEMBLY 746
PPC VALVE .760
REMOVAL .760
INSTALLATION 761
DISASSEMBLY AND ASSEMBLY 762
MAIN CONTROL VALVE 763
REMOVAL .763
INSTALLATION 765
DISASSEMBLY .768
ASSEMBLY 770
DUMP CYLINDER .772
REMOVAL .772
INSTALLATION 774
LIFT CYLINDER .776
REMOVAL .776
INSTALLATION 778
STEERING, LIFT, DUMP CYLINDER .780
DISASSEMBLY .780
ASSEMBLY 782
CENTER HINGE PIN 784
REMOVAL .784
INSTALLATION 790
WORK EQUIPMENT 800
REMOVAL .800
INSTALLATION 806
COUNTERWEIGHT .812
REMOVAL .812
INSTALLATION 813
FUEL TANK .814
REMOVAL .814
INSTALLATION 816
MACHINE MONITOR .818
REMOVAL .818
INSTALLATION 819
40 MAINTENANCE STANDARD .821
ENGINE AND TRANSMISSION MOUNT .823
DAMPER .824
TORQUE CONVERTER CHARGING, COOLING AND PPC PUMP 826
TORQUE CONVERTER AND PTO .828
TORQUE CONVERTER REGULATOR VALVE .829
TRANSMISSION 830
TRANSMISSION CONTROL VALVE 834
TRANSMISSION SOLENOID VALVE .838
TRANSFER .840
DRIVE SHAFT .842
CENTER SUPPORT .843
DIFFERENTIAL 844
FINAL DRIVE 846
AXLE MOUNT .848
CENTER HINGE PIN .850
STEERING LINKAGE AND STEERING COLUMN .852
STEERING GEAR BOX 854
STEERING VALVE .856
DIVERTER VALVE .858
STEERING CYLINDER MOUNT 859
EMERGENCY STEERING PUMP 860
BRAKE CHAMBER 861
BRAKE VALVE 862
SLACK ADJUSTER .864
BRAKE .866
PARKING BRAKE 868
SPRING CYLINDER 869
CONTROL PUMP .870
MAIN CONTROL VALVE .871
PPC VALVE 872
CYLINDER 874
BUCKET LINKAGE 876
BUCKET POSITIONER AND BOOM KICK-OUT .878

DESCRIPTION:

Komatsu WA700-1 Wheel Loader Shop Manual SEBM009501 – PDF DOWNLOAD

• SERIAL NUMBERS VVA700-1 – 15001 and up

G.B 25/12/24