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Komatsu WB97R-5 Backhoe Loader Shop Manual (F50003 and up) – PDF DOWNLOAD
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Komatsu WB97R-5 Backhoe Loader Shop Manual (F50003 and up)
SERIAL NUMBER : WB97R-5 F50003 and up
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Description
Komatsu WB97R-5 Backhoe Loader Shop Manual (F50003 and up)
FILE DETAILS:
Komatsu WB97R-5 Backhoe Loader Shop Manual
File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : WEBM006300
Total Pages : 588
DESCRIPTION:
Komatsu WB97R-5 Backhoe 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 eachr component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WB97R-5 Backhoe Loader Shop Manual
WEBM006300_WB97R-5.............................................................................................. 1 CONTENTS.................................................................................................... 3 REVISED PAGES............................................................................................... 5 k SAFETY.................................................................................................... 7 FOREWORD.................................................................................................... 9 HOW TO READ THE SHOP MANUAL................................................................................. 10 HOISTING INSTRUCTIONS....................................................................................... 11 STANDARD TIGHTENING TORQUE.................................................................................. 12 COATING MATERIALS........................................................................................... 14 ELECTRIC.................................................................................................... 15 WEIGHT TABLE................................................................................................ 16 TABLE OF OIL AND COOLANT QUANTITIES......................................................................... 17 CONVERSION TABLE............................................................................................ 19 10 STRUCTURE AND FUNCTION................................................................................... 27 POWER TRAIN............................................................................................. 28 TRANSMISSION (4WD)...................................................................................... 30 TRANSMISSION............................................................................................ 32 CONTROL VALVE BLOCK..................................................................................... 34 DRIVE SHAFTS............................................................................................ 35 FRONT AXLE.............................................................................................. 37 REAR AXLE............................................................................................... 40 HYDRAULIC CIRCUIT....................................................................................... 45 HYDRAULIC PUMP.......................................................................................... 47 1. MAIN PUMP........................................................................................ 48 2. DELIVERY CONTROL VALVE........................................................................... 53 8-SPOOL CONTROL VALVE................................................................................... 62 10-SPOOL CONTROL VALVE.................................................................................. 68 CLSS.................................................................................................... 75 1. DESCRIPTION...................................................................................... 75 2. OPERATING PRINCIPLES............................................................................. 76 3. OPERATION FOR EACH CIRCUIT AND VALVE............................................................. 78 STEERING UNIT........................................................................................... 94 PPC VALVES.............................................................................................. 95 SHOVEL PPC VALVE (STANDARD)......................................................................... 95 SHOVEL PPC VALVE (FLOAT + RETURN TO DIG)............................................................ 99 OUTRIGGERS PPC VALVE................................................................................105 BACKHOE LH PPC VALVE................................................................................110 BACKHOE RH PPC VALVE................................................................................111 SOLENOID VALVE GROUP (EV1)..............................................................................112 BACKHOE VERSION WITHOUT 4 IN 1 BUCKET...............................................................112 BACKHOE VERSION WITH 4 IN 1 BUCKET..................................................................113 SAFETY VALVES...........................................................................................114 SHOVEL RAISE........................................................................................114 SHOVEL DUMP.........................................................................................115 BOOM................................................................................................116 ARM.................................................................................................117 SHOVEL CYLINDERS........................................................................................118 RAISING CYLINDER....................................................................................118 DUMPING CYLINDER....................................................................................118 4 IN 1 BUCKET.......................................................................................119 BACKHOE CYLINDERS.......................................................................................120 BOOM CYLINDER.......................................................................................120 ARM.................................................................................................120 BUCKET CYLINDER.....................................................................................121 OUTRIGGER CYLINDER..................................................................................121 BOOM SWING CYLINDER.................................................................................122 JIG ARM CYLINDER....................................................................................122 AIR-CONDITIONING UNIT...................................................................................124 OPERATION OF THE AIR CONDITIONING UNIT..................................................................125 FUSE AND RELAY CENTRE...................................................................................127 DRIVER SEAT WIRING......................................................................................128 SWITCH PANEL WIRING.....................................................................................129 FRONT DASH WIRING.......................................................................................130 LATERAL DASH WIRING.....................................................................................131 ROOF WIRING.............................................................................................132 ENGINE WIRING...........................................................................................133 SPEED SELECTOR WIRING...................................................................................134 BACKHOE WIRING..........................................................................................135 JIG ARM WIRING..........................................................................................136 WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)...................................................137 20 TESTING AND ADJUSTMENTS..................................................................................139 NORMAL OR STANDARD TECHNICAL DATA.......................................................................141 SPECIAL TOOLS...........................................................................................156 ADJUSTING VALVE CLEARANCE...............................................................................157 ENGINE SPEED TESTS......................................................................................158 TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT.........................................................160 BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE..............................................161 ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER................................................163 ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...................................................................165 BRAKING SYSTEM CHECKS...................................................................................166 PARKING BRAKE ADJUSTMENT................................................................................169 CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT......................................170 CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES................................................172 SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES..................................................176 CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE - ADJUSTING THE LS VALVE............................178 CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY PRESSURE....................................................180 ADJUSTING THE PC VALVE..................................................................................181 TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....................................................182 CHECKING FOR LEAKS IN THE STEERING CYLINDERS............................................................183 TESTING PRESSURES IN THE POWER TRAIN GROUP..............................................................184 TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES..............................................186 ANALYSIS OF CAUSES HYDRAULIC DRIFT......................................................................187 FRONT EQUIPMENT.....................................................................................187 BACKHOE.............................................................................................189 TESTING THE AIR-CONDITIONING UNIT.......................................................................192 EMPTYING THE AIR-CONDITIONING UNIT......................................................................194 TROUBLESHOOTING.........................................................................................195 FRONT AXLE TROUBLESHOOTING..........................................................................195 FRONT AXLE CHECKING AND TROUBLESHOOTING.............................................................198 REAR AXLE TROUBLESHOOTING...........................................................................200 REAR AXLE CHECKING AND TROUBLESHOOTING..............................................................203 TRANSMISSION TROUBLESHOOTING........................................................................205 30 REMOVAL AND INSTALLATION.................................................................................209 HOW TO READ THE MANUAL..................................................................................211 PRECAUTIONS TO BE TAKEN WHILE WORKING...................................................................212 SPECIAL TOOLS...........................................................................................213 ENGINE HOOD.............................................................................................217 Removal.............................................................................................217 Installation........................................................................................218 FRONT GUARD.............................................................................................219 Removal.............................................................................................219 Installation........................................................................................219 RADIATOR GROUP..........................................................................................220 Removal.............................................................................................220 Installation........................................................................................223 CONDENSER (For machines equipped with an air-conditioning unit).........................................224 Removal.............................................................................................224 Installation........................................................................................224 MUFFLER.................................................................................................225 Removal.............................................................................................225 Installation........................................................................................225 AIR FILTER..............................................................................................226 Removal.............................................................................................226 Installation........................................................................................226 TURBOCHARGER............................................................................................227 Removal.............................................................................................227 Installation........................................................................................228 AIR-CONDITIONING UNIT COMPRESSOR........................................................................229 Removal.............................................................................................229 Installation........................................................................................230 AIR-CONDITIONING UNIT COMPRESSOR BELT...................................................................231 Removal.............................................................................................231 Installation........................................................................................232 EXHAUST PIPE............................................................................................233 Removal.............................................................................................233 Installation........................................................................................233 FAN AND HEATING GROUP...................................................................................234 Removal.............................................................................................234 Installation........................................................................................239 BATTERY.................................................................................................240 Removal.............................................................................................240 Installation........................................................................................241 FUEL TANK...............................................................................................242 Removal.............................................................................................242 Installation........................................................................................243 STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....244 Removal.............................................................................................244 Installation........................................................................................245 WORKING BRAKE PUMP GROUP................................................................................246 Removal.............................................................................................246 Installation........................................................................................248 STEERING UNIT...........................................................................................249 Removal.............................................................................................249 Installation........................................................................................250 CAB.....................................................................................................251 Removal.............................................................................................251 Installation........................................................................................257 HYDRAULIC OIL TANK......................................................................................259 Removal.............................................................................................259 Installation........................................................................................265 PISTON PUMP.............................................................................................266 Removal.............................................................................................266 Installation........................................................................................267 TRANSMISSION............................................................................................268 Removal.............................................................................................268 Installation........................................................................................272 Disassembly and assembly............................................................................273 CONVERTOR...............................................................................................381 Removal.............................................................................................381 Installation........................................................................................381 ENGINE..................................................................................................382 Removal.............................................................................................382 Installation........................................................................................386 CONTROL VALVE...........................................................................................387 Removal.............................................................................................387 Installation........................................................................................389 FRONT AXLE..............................................................................................390 Removal.............................................................................................390 Installation........................................................................................392 Disassembly and assembly............................................................................393 REAR AXLE...............................................................................................426 Removal.............................................................................................426 Installation........................................................................................428 Disassembly and assembly............................................................................429 SHOVEL PPC VALVE........................................................................................479 Removal.............................................................................................479 Installation........................................................................................480 SHOVEL LIFT CYLINDERS...................................................................................481 Removal.............................................................................................481 Installation........................................................................................482 SHOVEL DUMP CYLINDERS...................................................................................483 Removal.............................................................................................483 Installation........................................................................................484 SHOVEL..................................................................................................485 Removal.............................................................................................485 Installation........................................................................................485 FRONT WORKING EQUIPMENT.................................................................................486 Removal.............................................................................................486 Installation........................................................................................487 BACKHOE PPC VALVES......................................................................................488 Removal.............................................................................................488 Installation........................................................................................489 PPC VALVE SUPPORT RELEASE CABLES........................................................................490 Removal.............................................................................................490 Installation and adjusting..........................................................................492 PPC VALVE SUPPORT RETURN GAS SPRING.....................................................................493 Removal.............................................................................................493 Installation........................................................................................494 SOLENOID VALVE GROUP (servocontrol and optional attachment).............................................495 Removal.............................................................................................495 Installation........................................................................................496 BACKHOE BOOM CYLINDER...................................................................................497 Removal.............................................................................................497 Installation........................................................................................499 ARM CYLINDER............................................................................................500 Removal.............................................................................................500 Installation........................................................................................501 JIG ARM CYLINDER........................................................................................502 Removal.............................................................................................502 Installation........................................................................................502 OUTRIGGER CYLINDER......................................................................................503 Removal.............................................................................................503 Installation........................................................................................504 BACKHOE SWING CYLINDERS.................................................................................505 Removal.............................................................................................505 Installation........................................................................................507 BACKHOE BUCKET CYLINDER.................................................................................508 Removal.............................................................................................508 Installation........................................................................................509 BACKHOE BOOM SAFETY CYLINDER............................................................................510 Removal.............................................................................................510 Installation........................................................................................511 CYLINDER................................................................................................512 SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS...................................................512 Disassembly.....................................................................................512 Assembly........................................................................................514 BACKHOE SWING CYLINDERS.............................................................................517 Disassembly.....................................................................................517 Assembly........................................................................................520 BACKHOE WORKING EQUIPMENT...............................................................................523 Removal.............................................................................................523 Installation........................................................................................524 BACKHOE BUCKET..........................................................................................525 Removal.............................................................................................525 Installation........................................................................................525 BACKHOE BOOM CYLINDER...................................................................................526 Removal.............................................................................................526 Installation........................................................................................526 ARM.....................................................................................................527 Removal.............................................................................................527 Installation........................................................................................527 JIG ARM.................................................................................................528 Removal.............................................................................................528 Installation........................................................................................528 2nd ARM.................................................................................................529 Removal.............................................................................................529 Installation........................................................................................529 2nd ARM GUIDES..........................................................................................530 Removal.............................................................................................530 Installation........................................................................................530 BACKHOE SWING BRACKET...................................................................................531 Removal.............................................................................................531 Installation........................................................................................531 COMPLETE BACKHOE BACKFRAME..............................................................................532 Removal.............................................................................................532 Installation........................................................................................533 BACKFRAME LOCK PISTONS..................................................................................534 Removal.............................................................................................534 Installation........................................................................................535 40 STANDARD MAINTENANCE.....................................................................................537 TRANSMISSION............................................................................................538 FRONT AXLE..............................................................................................541 REAR AXLE...............................................................................................545 HYDRAULIC PUMP..........................................................................................549 CONTROL VALVE...........................................................................................552 8-SPOOL VERSION.....................................................................................552 10-SPOOL VERSION....................................................................................560 PPC VALVES..............................................................................................568 SHOVEL CONTROL......................................................................................568 SHOVEL CYLINDERS........................................................................................570 DUMP CYLINDER.......................................................................................570 RAISE CYLINDER......................................................................................570 4 IN 1 BUCKET.......................................................................................571 BACKHOE CYLINDERS.......................................................................................572 BOOM................................................................................................572 ARM.................................................................................................572 BUCKET..............................................................................................572 BOOM SWING..........................................................................................573 OUTRIGGERS..........................................................................................574 JIG ARM.............................................................................................574 FRONT WORKING EQUIPMENT.................................................................................576 SWING BRACKET...........................................................................................578 BACKHOE WORKING EQUIPMENT...............................................................................580 90 VARIE....................................................................................................583 ELECTRICAL DIAGRAM (STANDARD VERSION)...................................................................585
KOMATSU WB97R-5 BACKHOE LOADER SHOP MANUAL (F50003 AND UP) – PDF DOWNLOAD:
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