Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09001- PDF DOWNLOAD

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Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09001 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09001 – PDF DOWNLOAD

Language : English
Pages : 1000
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09001 – PDF DOWNLOAD

Model: Serial number:

• WA70M-8E0 H71051 and up

VENBM09001 WA70M-8E0 1
INDEX AND FOREWORD 3
ABBREVIATION LIST . 4
List of abbreviations used in the text 4
List of abbreviations used in the circuit diagrams 9
FOREWORD, SAFETY, BASIC INFORMATION . 10
HOW TO READ THE SHOP MANUAL . 10
Composition of the shop manual 10
Symbols . 12
Signal word . 12
Unit 12
SAFETY NOTICE FOR OPERATION . 13
Safety matters 13
General precautions . 14
Precautions for preparatory work 15
Precautions during work . 15
Precautions for slinging work and making signals 17
Precautions for using mobile crane 20
Precautions for using overhead traveling crane 20
Selecting wire ropes 21
PRECAUTIONS TO PREVENT FIRE . 23
Fire caused by fuel, oil, coolant or window washer fluid 23
Fire caused by accumulation or attachment of flammable material . 23
Fire coming from electric wiring 23
Fire caused by piping . 24
Fire around the machine due to highly heated exhaust gas 24
Explosion caused by lighting equipment 24
ACTIONS IF FIRE OCCURS 25
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 26
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 27
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 28
Select an appropriate workplace . 28
Disassembly and maintenance work in the field . 28
Sealing of openings (prevention of flowing out of oil) 28
Preventing intrusion of foreign materials during refilling 29
Replacing hydraulic oil while its temperature is high . 29
Avoid reusing the hydraulic oil and lubricating oil . 29
Flushing operation 29
Cleaning operation 30
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 31
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 42
Defective contact of connectors (defective contact between male and female connectors) 42
Defective crimping or soldering of connectors . 43
Disconnection in wiring . 43
Water entering the connector by high-pressure jetting . 43
Entry of water, dirt, or dust when disconnecting a connector 43
Oil, mud, or dust stuck to connector 44
Select an appropriate workplace . 45
Sealing the opening . 45
How to clean parts when dirt is stuck . 45
Precautions for replacing fuel filter cartridge . 45
Select an appropriate workplace . 46
Sealing the opening . 46
PRACTICAL USE OF KOMTRAX 47
Merit of using KOMTRAX 47
How to make a full use of KOMTRAX . 48
How to operate KOMTRAX 48
Disconnecting connectors 49
Connecting connectors . 50
Drying wiring harness . 52
Handling controller . 53
Method for disconnecting Deutsch connector 54
Method for connecting Deutsch connector . 54
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) . 55
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 55
Method for disconnecting slide lock type connector (FRAMATOME-24) . 55
Method for connecting slide lock type connector (FRAMATOME-24) 56
Method for disconnecting connector with lock to pull 57
Method for connecting connector with lock to pull . 57
Method for disconnecting connector with lock to push (BOSCH-3) 58
Method for connecting connector with lock to push (BOSCH-3) . 58
Method for disconnecting connector with lock to push (AMP-3) 59
Method for connecting connector with lock to push (AMP-3) . 59
Method for disconnecting connector with lock to push (SUMITOMO-3) . 59
Method for connecting connector with lock to push (SUMITOMO-3) 59
Method for disconnecting connector with lock to push (SUMITOMO-4) . 59
Method for connecting connector with lock to push (SUMITOMO-4) 59
Method for disconnecting connector with housing to rotate . 60
Method for connecting connector with housing to rotate 60
Method for connecting ring terminals and strip fuses to power stud of printed circuit boards 61
HOW TO READ ELECTRICAL WIRE CODE 62
TYPE, SYMBOL, AND MATERIAL 62
COLOR CODES TABLE . 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 64
STANDARD DIMENSION AND TOLERANCE 64
STANDARD CLEARANCE AND STANDARD VALUE . 65
STANDARD INTERFERENCE . 65
REPAIR LIMIT AND ALLOWABLE VALUE OR ALLOWABLE DIMENSION . 65
ALLOWABLE CLEARANCE . 66
ALLOWABLE INTERFERENCE 66
STANDARD TIGHTENING TORQUE TABLE 67
CONVERSION TABLE 75
METHOD OF USING THE CONVERSION TABLE 75
EXAMPLES OF USING THE CONVERSION TABLE TO CONVERT A UNIT FROM MM TO IN 75
TEMPERATURE . 79
SPECIFICATIONS 83
DIMENSIONS, WEIGHTS AND OPERATING DATA 84
SPECIFICATIONS 86
WEIGHT TABLES . 87
LUBRICANTS AND OPERATING MEDIUMS 88
BASIC PROCEDURES OF MAINTENANCE . 90
OIL . 90
FUEL 90
COOLANT . 91
GREASE 91
STORING OIL AND FUEL 91
FILTERS . 92
OUTLINE OF ELECTRIC SYSTEM 92
TIGHTENING TORQUE LIST – METRIC SCREWS AND NUTS . 93
STRUCTURE AND FUNCTION 95
ABBREVIATION LIST . 99
List of abbreviations used in the text 99
List of abbreviations used in the circuit diagrams 104
ELECTRICAL SYSTEM . 105
BOOT-UP SYSTEM 106
LAYOUT DRAWING OF BOOT-UP SYSTEM 106
AROUND THE CAB AND FLOOR 107
BATTERY DISCONNECT SWITCH . 108
FUNCTION OF BATTERY DISCONNECT SWITCH . 108
PREHEATING SYSTEM . 110
FUNCTION OF AUTOMATIC PREHEATING SYSTEM . 111
OPERATION OF AUTOMATIC PREHEATING SYSTEM 111
ENGINE SYSTEM . 112
LAYOUT DRAWING OF ENGINE SYSTEM . 112
COOLING SYSTEM 113
LAYOUT DRAWING OF COOLING SYSTEM 113
SPECIFICATIONS OF COOLING SYSTEM 114
COOLING FAN CONTROL SYSTEM 115
FUNCTION OF COOLING FAN CONTROL SYSTEM 116
COOLING FAN REVERSE ROTATION FUNCTION (Option) 116
COMPONENT PARTS OF COOLING SYSTEM . 117
STRUCTURE OF COOLING FAN MOTOR 117
CONTROL SYSTEM 118
AROUND THE CAB AND FLOOR 119
MACHINE MONITOR SYSTEM 120
MACHINE MONITOR SYSTEM DIAGRAM 120
KOMTRAX SYSTEM 121
KOMTRAX SYSTEM DIAGRAM 121
FUNCTION OF KOMTRAX SYSTEM 121
COMPONENT PARTS OF CONTROL SYSTEM . 122
MACHINE MONITOR . 122
Function of KOMTRAX terminal 132
HST CONTROLLER 134
Structure of HST controller . 134
Real time monitoring function . 134
Self-diagnosis function . 134
CAN TERMINATING RESISTOR 138
Function of CAN terminating resistor 138
ENGINE CONTROLLER . 139
Real time monitoring function . 139
Self-diagnosis function . 139
ACCELERATOR PEDAL . 140
Acceleration signal . 140
Idling validation signal 140
Output Characteristics 141
HYDRAULIC SYSTEM 142
Structure of hydraulic tank . 143
Specifications of hydraulic tank 143
Structure of main control valve . 145
POWER TRAIN SYSTEM 147
OPERATION OF POWER TRAIN SYSTEM . 148
FUNCTION OF THE CLOSED CIRCUIT SYSTEM . 150
SPECIFICATIONS OF THE HST SYSTEM 150
STRUCTURE OF THE HST SYSTEM . 151
20km/h without SpeedControl . 151
COMPONENT PARTS OF POWER TRAIN SYSTEM . 152
Structure of drive shaft 152
Function of drive shaft . 152
Structure of HST pump . 153
Operation of HST pump . 154
Components of HST pump 155
HST motor . 157
Structure of transfer box . 158
Function of transfer box 159
Structure of front axle . 160
Structure of rear axle 161
Function of differential 161
Function of towing system . 163
WORK EQUIPMENT SYSTEM . 164
Layout of work equipment system . 164
WORK EQUIPMENT LOCK SYSTEM 166
ECSS (Option) . 167
Function of ECSS 167
Operation of ECSS . 167
RETURN TO DIG (option) 168
Structure . 168
Function 168
Main control valve 169
Emergency lowering 169
Loader Linkage with quick-coupler . 171
STEERING SYSTEM . 173
STEERING COLUMN . 174
Structure of steering column 174
General view 174
PRIORITY VALVE 177
ORBITROL-VALVE 178
STEERING RELIEF VALVE . 179
BRAKE SYSTEM 180
LAYOUT DRAWING OF BRAKE SYSTEM 180
SERVICE BRAKE ASSEMBLY 181
Inching Function 181
PARKING BRAKE ASSEMBLY 182
STRUCTURE OF 182
UNDERCARRIAGE AND FRAME . 183
Rear axle mount . 184
Frame, axle mount and center hinge pin 185
TIRE 186
Structure of radial tire 186
General view 186
Structure . 186
Structure of bias tire 187
General view 187
Structure . 187
WORK EQUIPMENT 188
STRUCTURE OF WORK EQUIPMENT . 188
STRUCTURE OF BUCKET . 189
General view and sectional view . 189
CAB AND ITS ATTACHMENTS . 190
ROPS FOPS CAB . 190
Structure of ROPS FOPS cab 190
Function of ROPS FOPS cab . 191
CAB MOUNT . 192
Structure of cab mount 192
General view 192
Function of cab mount . 192
STANDARD VALUE TABLE 203
ABBREVIATION LIST . 204
List of abbreviations used in the text 204
List of abbreviations used in the circuit diagrams 209
STANDARD VALUE TABLE 210
Standard value table for engine . 210
Standard value table for chassis 211
TEST CERTIFICATE 213
TESTING AND ADJUSTING . 215
ABBREVIATION LIST . 219
List of abbreviations used in the text 219
List of abbreviations used in the circuit diagrams 225
TEST ENGINE WITH SOFTWARE TOOL 226
CONNECTION OF A COMPUTER TO THE MACHINE . 226
ENGINE AND COOLING SYSTEM . 228
TEST ENGINE SPEED . 228
Method for testing engine speed . 228
Method for testing engine low idle speed 228
Method for testing engine high idle speed . 229
Method for testing engine speed HST stall . 230
Method for testing engine speed at hydraulic stall 231
Method for testing engine speed at full stall (HST stall and hydraulic stall) . 232
TEST EXHAUST GAS COLOUR . 234
Testing tool for exhaust gas colour . 234
TEST AND ADJUST VALVE CLEARANCE . 236
METHOD FOR TESTING AND ADJUSTINGVALVE CLEARANCE . 237
TEST COMPRESSION PRESSURE . 238
METHOD FOR TESTING COMPRESSION PRESSURE . 238
Compression pressure inspection procedures 239
Injector reassembly procedures 240
TEST ENGINE OIL PRESSURE 241
METHOD FOR TESTING ENGINE OIL PRESSURE 241
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 242
TEST FUEL CIRCUIT FOR LEAKAGE . 243
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 243
Testing method of fuel circuit for leakage at engine stopped 243
Testing method of fuel circuit for leakage at engine low idle . 244
Testing method of fuel circuit for leakage at engine high idle 244
HANDLE NO-INJECTION CRANKING OPERATION 245
TEST DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 246
METHOD FOR TESTING DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 246
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 247
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 247
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS . 248
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS . 248
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 249
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 249
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 250
TEST ALTERNATOR BELT 251
METHOD FOR TESTING ALTERNATOR BELT 251
POWER TRAIN . 252
TEST AND ADJUST HST PRESSURE CUT OFF 252
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 253
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 253
STEERING SYSTEM . 254
Operating time for steering wheel . 254
Operating force of steering wheel . 255
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE . 256
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 257
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 258
BLEED AIR FROM STEERING CYLINDER CIRCUIT 259
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 259
BLEED AIR FROM BRAKE CIRCUIT 260
TEST BRAKING PERFORMANCE 262
MEASURING THE STOPPING DISTANCE . 262
TEST AND ADJUST BRAKE PEDAL . 263
TEST WEAR OF WHEEL BRAKE PADS . 264
TEST PARKING BRAKE PERFORMANCE 265
HYDRAULIC SYSTEM 266
Release the remaining pressure from small accumulator for safety valves (option) 266
Releasing the remaining pressure in ECSS 268
TEST AND ADJUST WORK EQUIPMENT PRESSURE . 269
TEST BOOST PRESSURE . 270
TESTING AND ADJUSTING COOLING FAN SPEED . 271
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE . 273
METHOD FOR TESTING THE ECSS ACCUMULATOR NITROGEN GAS PRESSURE . 274
METHOD FOR CHARGING THE ECSS ACCUMULATOR WITH NITROGEN GAS 275
ELECTRICAL SYSTEM . 277
SET AND ADJUST EACH EQUIPMENT . 277
SET AND OPERATE MACHINE MONITOR . 278
Switch panel 278
Operator mode and service mode of machine monitor . 279
OPERATOR MODE . 281
Setting usage limitation (password) . 281
Change password . 282
SERVICE MODE 283
METHOD FOR OPERATING SERVICE MODE . 283
Table of self-define monitoring . 287
ABNORMALITY RECORD MENU . 296
Method for cleaning abnormality record 299
DEFAULT MENU 309
METHOD FOR SETTING WITH DEFAULT SETTING MENU (OPTION SELECTION) . 311
ADJUSTMENT MENU . 315
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (T/C DEVICE CALIBRATION) 315
HANDLE BATTERY DISCONNECT SWITCH 318
TEST DIODES . 320
TROUBLESHOOTING . 323
ABBREVIATION LIST . 327
List of abbreviations used in the text 327
List of abbreviations used in the circuit diagrams 333
RELATED INFORMATION ON TROUBLESHOOTING 334
GENERAL TROUBLESHOOTING POINTS 334
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 336
CHECKS BEFORE TROUBLESHOOTING . 338
Engine, lubricating oil and coolant . 338
Hydraulic and mechanical equipment 338
Electric equipment 339
Exterior 339
Interior 339
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 340
WALK-AROUND CHECK . 340
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 342
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 343
CONNECTOR LOCATION LIST . 345
CONNECTOR CONTACT IDENTIFICATION 353
SPARE FUSES AND RELAY . 390
USB socket on central electric board (CEB) 395
FAILURE CODES TABLE . 398
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF HST-CONTROLLER CODE) 415
POWER ON 416
8.2.1 Documentation of Power On (PwrOn) . 416
8.2.1 – 2 Interface . 416
8.2.1 – 3 Description . 417
8.2.1 – 3.3 State 2: Check sensor supply voltages . 420
8.2.1 – 3.4 State 3: Check hardware monitoring errors . 420
8.2.1 – 3.5 State 4: Check first application specific start condition . 420
8.2.1 – 3.6 State 5: Check central switch . 420
8.2.1 – 3.7 State 6: Configure safouts 421
8.2.1 – 3.8 State 7: Check safouts 421
8.2.1 – 3.9 State 8: Check diesel engine speed 421
8.2.1 – 3.10 State 9: Enable sensor supply monitoring . 422
8.2.1 – 3.11 State 10: Check hardware monitoring errors . 422
8.2.1 – 3.12 State 11: Check second applications specific start condition . 422
8.2.1 – 3.12 State 11: Check second applications specific start condition . 422
8.2.1 – 3.13 State 12: Run 422
8.2.1 – 3.14 Diagnosis Configuration Notes 422
8.2.1 – 4 Input Signals . 423
8.2.1 – 5 Parameters 424
8.2.1 – 6 Output Signals 424
8.2.1 – 7 Error Information . 424
Abbreviations for Failure Code (HST-controller) . 426
FAILURE CODE (#R0CIB) . 427
FAILURE CODE (#R0CKB) . 428
FAILURE CODE (#R0CLB) . 429
FAILURE CODE (#R0CMB) . 430
FAILURE CODE (#R0CPV) . 431
FAILURE CODE (#R0CQB) . 432
FAILURE CODE (#R0CRB) . 433
FAILURE CODE (#R0CSB) . 434
FAILURE CODE (#R0CTB) . 435
FAILURE CODE (#R0CWB) . 436
FAILURE CODE (#R0JLB) . 437
FAILURE CODE (#R0JMB) . 438
FAILURE CODE (#R0JNB) . 439
FAILURE CODE (#R0JOB) . 440
FAILURE CODE (#R0JPB) . 441
FAILURE CODE (#R0QR2) . 442
FAILURE CODE (#R0QS2) . 443
FAILURE CODE (#R0QT4) . 444
FAILURE CODE (#R0QU3) . 445
FAILURE CODE (#R0QV4) . 446
FAILURE CODE (#R0QY4) . 447
FAILURE CODE (#R0R0V) . 448
FAILURE CODE (#R0R1V) . 449
FAILURE CODE (#R0SHV) . 450
FAILURE CODE (#R0SJV) . 451
FAILURE CODE (#R0XU2) . 452
FAILURE CODE (#R0XU3) . 453
FAILURE CODE (#R0XU4) . 454
FAILURE CODE (#R0XUB) . 455
FAILURE CODE (#R0XV2) . 456
FAILURE CODE (#R0XV3) . 457
FAILURE CODE (#R0XV4) . 458
FAILURE CODE (#R0XVB) . 459
FAILURE CODE (#R0XW2) . 460
FAILURE CODE (#R0XW3) . 461
FAILURE CODE (#R0XW4) . 462
FAILURE CODE (#R0XWB) . 463
FAILURE CODE (#R14W2) . 464
FAILURE CODE (#R14WB) . 465
FAILURE CODE (#R14X2) . 466
FAILURE CODE (#R14XB) . 467
FAILURE CODE (#R14Y3) . 468
FAILURE CODE (#R14YV) . 469
FAILURE CODE (#R14Z2) . 470
FAILURE CODE (#R14ZB) . 471
FAILURE CODE (#R1502) . 472
FAILURE CODE (#R150B) . 473
FAILURE CODE (#R1532) . 474
FAILURE CODE (#R153B) . 475
FAILURE CODE (#R1KWJ) . 476
FAILURE CODE (#R1KWV) . 477
FAILURE CODE (#R1L0B) . 478
FAILURE CODE (#R1L2B) . 479
FAILURE CODE (#R1L4B) . 480
FAILURE CODE (#R1R4B) . 481
FAILURE CODE (#R2690) . 482
FAILURE CODE (#R2691) . 483
FAILURE CODE (#R2694) . 484
FAILURE CODE (#R269B) . 485
FAILURE CODE (#R26B0) . 486
FAILURE CODE (#R26B1) . 487
FAILURE CODE (#R26B4) . 488
FAILURE CODE (#R26BB) . 489
FAILURE CODE (#R26OB) . 490
FAILURE CODE (#R26P0) . 491
FAILURE CODE (#R26P1) . 492
FAILURE CODE (#R26P4) . 493
FAILURE CODE (#R26PB) . 494
FAILURE CODE (#R2BKB) . 495
FAILURE CODE (#R2IPB) . 496
FAILURE CODE (#R2IQB) . 498
FAILURE CODE (#R2IRB) . 500
FAILURE CODE (#R2ITB) . 502
FAILURE CODE (#R2IUB) . 504
FAILURE CODE (#R2J4B) . 506
FAILURE CODE (#R2JK2) . 507
FAILURE CODE (#R2JK9) . 508
FAILURE CODE (#R2JKB) . 509
FAILURE CODE (#R2JKB) . 510
FAILURE CODE (#R2JL2) . 511
FAILURE CODE (#R2JL9) . 512
FAILURE CODE (#R2JLB) . 513
FAILURE CODE (#R2JM2) . 514
FAILURE CODE (#R2JM9) . 515
FAILURE CODE (#R2JMB) . 516
FAILURE CODE (#R2JS2) . 517
FAILURE CODE (#R2JS9) . 518
FAILURE CODE (#R2JSB) . 519
FAILURE CODE (#R2JT2) . 520
FAILURE CODE (#R2JT9) . 521
FAILURE CODE (#R2JTB) . 522
FAILURE CODE (#R2JU2) . 523
FAILURE CODE (#R2JU9) . 524
FAILURE CODE (#R2JUB) . 525
FAILURE CODE (#R94Y2) . 526
FAILURE CODE (#R94YB) . 527
FAILURE CODE (#R9512) . 528
FAILURE CODE (#R951B) . 529
FAILURE CODE (#R968B) . 530
FAILURE CODE (#R9JLB) . 531
FAILURE CODE (#R9Q82) . 532
FAILURE CODE (#R9Q8B) . 533
FAILURE CODE (#R9Q8V) . 534
FAILURE CODE (#R9QDB) . 535
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E- MODE) 536
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) . 554
TROUBLESHOOTING OF ENGINE (S-MODE) 563
S-4 ENGINE STARTABILITY IS POOR . 567
S-9 EXHAUST SMOKE IS BLACK 575
S-12 FUEL CONSUMPTION IS EXCESSIVE 579
S-14 OIL PRESSURE DROPS . 581
S-18 UNUSUAL NOISE IS HEARD . 586
S-19 VIBRATION IS EXCESSIVE . 587
DISASSEMBLY AND ASSEMBLY 589
ABBREVIATION LIST . 591
List of abbreviations used in the text 591
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY . 596
HOW TO READ THIS MANUAL . 596
Reading the work procedures . 596
Reading the symbols . 596
Reading the signal word . 597
Reading the unit 597
COATING MATERIALS LIST 598
Adhesive 598
Liquid gasket . 599
Molybdenum disulfide lubricant 599
Seizure prevention compound . 600
Grease 600
Primer 601
Adhesive 601
Caulking material . 601
ENGINE AND COOLING SYSTEM . 602
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY . 602
Removal of supply pump assembly . 602
Reassembly of supply pump . 604
REMOVE AND INSTALL INJECTOR ASSEMBLY 606
Removal of injector . 606
Reassembly of injector 607
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY . 609
Remove cylinder head assembly . 610
Install the cylinder head . 613
REMOVE AND INSTALL EGR VALVE ASSEMBLY . 619
Remove the EGR cooler assembly 619
Remove the EGR valve 620
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 621
Removal of Starter Motor 621
Disassembly of Starter Motor 621
Reassembly of Starter Motor . 624
Install the Starter Motor . 625
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 626
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT . 626
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT . 627
REMOVE AND INSTALL ALTERNATOR BELT 628
REMOVE AND INSTALL ALTERNATOR ASSEMBLY 630
Remove the alternator assembly 630
Disassemble the alternator assembly . 631
Reassemble the alternator assembly 632
Install alternator assembly . 632
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY . 633
Removal of fan assembly . 633
Installation of fan assembly 634
REMOVE AND INSTALL RADIATOR AND HYDRAULIC TANK ASSEMBLY . 634
Removal of radiator and hydraulic tank assembly . 634
Installation of radiator and hydraulic tank assembly 637
REMOVE AND INSTALL ENGINE ASSEMBLY 638
Remove engine assembly 638
INSTALLATION OF ENGINE ASSEMBLY . 642
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 643
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY . 644
Removal of engine hood assembly consisting of plastic and steel hood 644
Removal of steel hood . 644
Installation of steel hood 645
Removal of engine hood assembly . 645
Installation of engine hood assembly 646
REMOVE AND INSTALL AFTERTREATMENT DEVICE 647
METHOD FOR REMOVING AFTER TREATMENT DEVICE ASSEMBLY . 648
REMOVE AND INSTALL FUEL TANK ASSEMBLY . 650
Remove the fuel tank 650
Installation of fuel tank . 651
Fuelling fuel tank 651
REMOVE AND INSTALL AIR CLEANER ASSEMBLY . 652
Removal of air cleaner assembly . 652
Installation of air cleaner assembly 653
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 653
Removal of air conditioner compressor assembly 654
Installation of air compressor assembly . 654
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY . 655
Remove air conditioner condenser assembly . 656
Installation of air conditioner condenser assembly 657
POWER TRAIN . 659
PUMP FOR STEERING, WORK EQUIPMENT, COOLING FAN 659
Removal of the pump for steering, work equipment and cooling fan 659
Installation of hydraulic pump assembly . 659
ARTICULATED JOINT ASSEMBLY 660
Removal of articulation joint assembly 660
Installation of articulation joint assembly . 660
HST MOTOR ASSEMBLY 661
Removal of HST motor assembly . 661
Installation of variable motor assembly . 662
HST PUMP ASSEMBLY . 663
Removal of HST pump assembly 663
Installation of variable motor assembly . 663
GEARBOX (TRANSFER ASSEMBLY) . 665
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY 665
SPECIFICATIONS 665
Conversion tables . 666
TORQUE SPECIFICATIONS . 667
Wheel nut tightening torques 668
Maintenance . 669
MANDATORY PROCEDURE . 670
End-stop plier setting 671
Input seal greasing . 672
Maintenance intervals . 673
Lubricant & Sealant specifications 674
SAFETY PRECAUTIONS 675
FLANGED REDUCTION GEAR 315 TYPE: INTEGRAL 315 INPUT GEAR 677
Exploded view . 677
Disassembly . 678
Assembly 681
PLANETARY REDUCTION GEAR 1: 4;23 684
Exploded view . 684
Disassembly . 685
Assembly 689
Special tools . 694
BEVEL PINION FLANGED TO REDUCTOR 696
Exploded view . 696
Disassembly . 697
Assembly 700
Special tools . 704
RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL 707
Exploded view . 707
Install and Adjust 708
INTEGRATED GEAR BOX . 711
Disassembly . 712
Assembly 716
Special Tool 720
REAR AXLE ASSEMBLY 721
Removal of rear axle assembly . 721
Installation of rear axle assembly 723
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS . 724
SAFETY PRECAUTIONS 724
PLANETARY REDUCTION AND AXLE SHAFT 725
Exploded view . 725
Disassembly . 726
Assembly 730
Special Tools . 734
RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL 736
Exploded view . 736
Install and adjust 737
DIFFERENTIAL WITH BLOCK TO SPHERES 100% . 740
Exploded view . 740
Disassembly . 741
Assembly 744
DIFFERENTIAL UNIT 45% . 747
Exploded view . 747
Disassembly . 748
Assembly 750
FRONT AXLE ASSEMBLY . 753
Removal of front axle assembly 753
Installation of front axle assembly . 754
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS . 755
Safety precautions 755
Lubricant & Sealant specifications 755
BRAKE: SERVICE BRAKE, NEGATIVE BRAKE, 100% LOCKED . 757
SAFETY PRECAUTIONS 757
Exploded view . 758
Brake working conditions 759
EMERGENCY RELEASE INSTRUCTIONS 763
Disassembly . 764
Assembly 770
Brake piston gap check 779
Special tools . 780
DISASSEMBLY AND ASSEMBLY OF NORMAL PRELOADED DIFFERENTIAL UNIT 781
SAFETY PRECAUTIONS 781
Exploded view . 782
Disassembly . 783
Assembly 786
PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45% 789
SAFETY PRECAUTIONS 789
Exploded view . 790
Disassembly . 791
Assembly 794
BEVEL PINION: NORMAL FLANGE AND NUT REVOLUTION COUNTER VERSION 797
SAFETY PRECAUTIONS 797
Exploded view . 798
Disassembly . 799
Assembly 802
Assembly: Revolution counter version 807
Special tools . 809
BEVEL PINION 814
SAFETY PRECAUTIONS 814
Exploded view . 815
Disassembly . 816
Assembly 818
Special tools . 822
RING AND PINION ADJUSTING: VERSION PINION COVER AND SINGLE ARM 826
SAFETY PRECAUTIONS 826
Exploded view . 827
Assembly 828
Special tools . 832
RING AND PINION ADJUSTING: VERSION PINION INTEGRAL AND DOUBLE ARM . 833
SAFETY PRECAUTIONS 833
Exploded view . 834
Assembly 835
UNDERCARRIAGE AND FRAME . 838
REMOVAL AND INSTALLATION OF COUNTERWEIGHTASSEMBLY . 838
Removal of counterweight assembly . 838
Installation of counterweight assembly 838
HYDRAULIC SYSTEM 839
REMOVE AND INSTALL LIFT CYLINDER ASSEMBLY . 839
Remove lift cylinder assembly . 839
Removal of lift cylinder assembly . 839
Install lift cylinder assembly 840
REMOVE AND INSTALL DUMP CYLINDER ASSEMBLY . 840
Remove dumb cylinder assembly . 840
Remove dump cylinder assembly . 840
Installation of dump cylinder assembly 841
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY . 841
Remove steering cylinder assembly . 842
Remove steering cylinder assembly . 842
Install steering cylinder assembly 842
WORK EQUIPMENT SYSTEM . 843
REMOVE AND INSTALL MAIN VALVE ASSEMBLY 843
Removal of main control valve assembly 843
Installation of main control valve assembly . 846
Removal of multifunction lever 847
REMOVE AND INSTALL QUICK COUPLER ASSEMBLY . 848
Remove quick coupler assembly . 848
Install quick coupler assembly 849
CAB AND ITS ATTACHMENTS . 850
REMOVE AND INSTALL OPERATOR‘S CAB GLASS (ADHERED GLASS) . 850
Preparation work for replacing the front window pane 851
Preparation work for replacing the rear window pane . 851
Preparation work for replacing the door window pane . 852
Left door assembly 852
Right door assembly . 852
Remove operator’s cab glass (adhered glass) . 852
Install operator’s cab glass (adhered glass) 854
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 856
Remove air conditioner unit assembly 857
Install heater unit assembly 859
REMOVE AND INSTALL OPERATOR‘S SEAT ASSEMBLY . 859
Remove operator‘s seat assembly (STD) . 859
Install operator‘s seat assembly (STD) 860
Remove operator‘s seat assembly (air suspension, heatable) 860
Install operator‘s seat assembly (air suspension, heatable) . 861
REMOVE AND INSTALL SEAT BELT 862
Remove seat belt on STD seat 862
Install seat belt on STD seat . 863
Remove seat belt on suspension, heatable seat . 863
Install seat belt on suspension, heatable seat 864
ELECTRICAL SYSTEM . 865
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY . 865
Method for removing engine controller assembly 866
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 868
Method for removing the cover of the console 868
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY . 869
Method for removing machine monitor assembly 869
Method for installing machine monitor assembly 872
REMOVE AND INSTALL CENTRAL ELECTRIC BOARD (CEB) . 873
Remove the cover of the console . 873
Remove central electric board (CEB) . 874
Remove I/O controller 64P . 874
Remove differential lock relay 874
Install differential lock rely 874
Install I/O controller 64P 875
Install central electric boar (CEB) . 875
Installation of the cover of the console 876
REMOVE AND INSTALL RELAYBOX . 878
Remove relaybox . 878
Remove battery relay 879
Remove the grommet frame from cables 879
Install the battery relay . 880
Install the grommet frame to cables . 880
Install relay box . 881
MAINTENANCE STANDARD 883
ABBREVIATION LIST . 885
List of abbreviations used in the text 885
List of abbreviations used in the circuit diagrams 890
ENGINE AND COOLING 891
MAINTENANCE STANDARD OF ENGINE MOUNT 891
MAINTENANCE STANDARD OF DAMPER 892
MAINTENANCE STANDARD OF COOLING FAN MOTOR . 893
POWER TRAIN . 894
MAINTENANCE STANDARD OF TRANSFER 894
MAINTENANCE STANDARD OF REAR AXLE . 895
MAINTENANCE STANDARD OF FRONT AXLE 896
BRAKE SYSTEM 897
MAINTENANCE STANDARD OF PARKING BRAKE . 897
HYDRAULIC SYSTEM 898
CAB AND ITS ATTACHMENTS . 902
Cabin – adjustment 902
APPENDIX 903
ABBREVIATION LIST . 905
List of abbreviations used in the text 905
List of abbreviations used in the circuit diagrams 910
AIR CONDITIONER SYSTEM 911
PRECAUTIONS FOR REFRIGERANT . 911
AIR CONDITIONER COMPONENT . 912
Specifications of air conditioner . 912
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE . 913
OUTLINE OF REFRIGERATION CYCLE 914
Compression (Compressor) 914
Condensation (Condenser) 914
Expansion (Expansion valve) . 914
Evaporation (Evaporator) 915
Relation between refrigerant and cooling trouble 915
AIR CONDITIONER TROUBLESHOOTING CHART . 917
Cooling trouble . 917
Heating trouble . 917
CONNECTION OF SERVICE TOOL 918
METHOD FOR CONNECTING SERVICE TOOL 919
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS . 920
Precautions for disconnection . 920
Precautions for connection 921
HANDLE COMPRESSOR OIL . 922
Management of compressor oil (SANDEN: SP-10 for use with R134a) . 922
Filling of compressor oil . 922
The quantity of compressor oil when the compressor is replaced 923
OTHER . 925
HYDRAULIC CIRCUIT DIAGRAM . 929
WIRING DIAGRAMS . 931
Contents 931
1-0 SYMBOLS SUMMARY, ABBREVIATIONS 932
1-1 HARNESS ARRANGEMENT DETAILS, JOYSTICK BUTTONS . 933
1-2 CAN BUS SUMMARY . 934
2-0 POWER SUPPLY, STARTER SWITCH 935
2-1 GROUNDING . 936
2-2 RELAYB., STARTER, ALTERN., BATTERY, GLOW PLUG . 937
2-3 MAIN ENGINE (EGR) RELAY, EGR VALVE 938
3-0 ECU, DPF SENS., REGENER. SW., SEC. ENG. STOP 939
3-1 ECU, ENGINE SENSORS . 940
3-2 INJECT., FUEL P., AIR CLEAN., TRAVEL PED., OIL PR . 941
4-0 MONITOR, I/O CONTROLLER 64P, BUZZER . 942
4-1 KOMTRAX CTRL, SERVICE CONNECTOR . 943
4-2 FLUID-SENSORS (OIL, FUEL, COOLANT), SPEED SENS 944
5-0 IMMOBILIZER, PARKING BRAKE, FNR SWITCH 945
5-1 HST CONTROLLER, DRIVING FUNCTIONS . 946
5-2 HST CONTROLLER INPUTS, AUTO INCH 947
5-3 CREEP . 948
6-0 FAN DRIVE, REVERSE FAN 949
7-0 AIR CONDITIONER, OPERATOR’S SEAT 950
7-1 WASHER, WIPER, REAR WINDOW HEATER, HORN . 951
8-0 LIGHTING FRONT 952
8-1 FLASHER . 953
8-2 REAR LIGHT, BACKUP AL., REAR FLASHER 954
8-3 WORK LAMPS 955
8-4 INTERIOR LAMP, ROTATING BEACON, PLUG BOX 956
9-0 ECSS, OVER CENTER VALVE . 957
9-1 RETURN TO DIG, QUICK COUPLER 958
9-2 RADIO, CLS, BLANK OPTION 959
W1 WIRING HARNESS LIST 960
W2 CONNECTOR LIST 1 . 961
W2 CONNECTOR LIST 2 . 962
W2 CONNECTOR LIST 3 . 963
W2 CONNECTOR LIST 4 . 964
W2 CONNECTOR LIST 5 . 965
W3 PIN LOCATION LIST 1 966
W3 PIN LOCATION LIST 2 967
W3 PIN LOCATION LIST 3 968
W3 PIN LOCATION LIST 4 969
W3 PIN LOCATION LIST 5 970
W3 PIN LOCATION LIST 6 971
W3 PIN LOCATION LIST 7 972
W3 PIN LOCATION LIST 8 973
W3 PIN LOCATION LIST 9 974
W3 PIN LOCATION LIST 10 . 975
W3 PIN LOCATION LIST 11 . 976
W3 PIN LOCATION LIST 12 . 977
W3 PIN LOCATION LIST 13 . 978
W3 PIN LOCATION LIST 14 . 979
W3 PIN LOCATION LIST 15 . 980
W3 PIN LOCATION LIST 16 . 981
W3 PIN LOCATION LIST 17 . 982
W3 PIN LOCATION LIST 18 . 983
W3 PIN LOCATION LIST 19 . 984
W3 PIN LOCATION LIST 20 . 985
W3 PIN LOCATION LIST 21 . 986
W3 PIN LOCATION LIST 22 . 987
W3 PIN LOCATION LIST 23 . 988
W3 PIN LOCATION LIST 24 . 989
W3 PIN LOCATION LIST 25 . 990
W3 PIN LOCATION LIST 26 . 991
W4 PIN LOCATION LIST 1 992
W4 PIN LOCATION LIST 2 993
W4 PARTS LIST 3 . 994
Connector diagram 1 . 997
Connector diagram 2 . 998
Connector diagram 3 . 999
Connector table for the operator‘s cab wiring harness (Part 1/2) 999
Connector diagram 4 .1000
Connector table for operator‘s cab wiring harness (Part 2/2) 1000

DESCRIPTION:

Komatsu WA70M-8E0 Wheel Loader Shop Manual VENBM09001 – PDF DOWNLOAD

Model: Serial number:

• WA70M-8E0 H71051 and up

G.B 30/12/24