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Komatsu WA700-1 Wheel Loader Shop Manual SEBM009501 – PDF DOWNLOAD
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Komatsu WA700-1 Wheel Loader Shop Manual
SERIAL NUMBERS : WA700-1 – 15001 andup
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Description
Komatsu WA700-1 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA700-1 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA700-1
Serial Number: 15001 and up
Book Code: SEBM009501
Language: English
Pages: 880
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA700-1 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 WA700-1 Wheel Loader Shop Manual
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
KOMATSU WA700-1 WHEEL LOADER SHOP MANUAL SEBM009501 – PDF DOWNLOAD:
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