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Komatsu WB97S-5 Backhoe Loader Shop Manual – PDF DOWNLOAD
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Description
Komatsu WB97S-5 Backhoe Loader Shop Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:616
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU WB97S-5 BACKHOE LOADER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WB97S-5 Backhoe Loader Shop Manual
FOREWORD:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
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 ADJUSTMENTS
This sections 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.
REMOVAL AND INSTALLATION
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.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WB97S-5 Backhoe Loader Shop Manual
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 STEERING SYSTEM (4WS)................................................................................... 44 HYDRAULIC CIRCUIT....................................................................................... 49 HYDRAULIC PUMP.......................................................................................... 51 1. MAIN PUMP........................................................................................ 52 2. DELIVERY CONTROL VALVE........................................................................... 57 8-SPOOL CONTROL VALVE................................................................................... 66 10-SPOOL CONTROL VALVE.................................................................................. 72 CLSS.................................................................................................... 79 1. DESCRIPTION...................................................................................... 79 2. OPERATING PRINCIPLES............................................................................. 80 3. OPERATION FOR EACH CIRCUIT AND VALVE............................................................. 82 STEERING UNIT........................................................................................... 98 PPC VALVES.............................................................................................. 99 SHOVEL PPC VALVE (STANDARD)......................................................................... 99 SHOVEL PPC VALVE (FLOAT + RETURN TO DIG)............................................................103 OUTRIGGERS PPC VALVE................................................................................109 BACKHOE LH PPC VALVE................................................................................114 BACKHOE RH PPC VALVE................................................................................115 SOLENOID VALVE GROUP (EV1)..............................................................................116 BACKHOE VERSION WITHOUT 4 IN 1 BUCKET...............................................................116 BACKHOE VERSION WITH 4 IN 1 BUCKET..................................................................117 SOLENOID VALVE GROUP (EV2)..............................................................................118 SAFETY VALVES...........................................................................................119 SHOVEL RAISE........................................................................................119 SHOVEL DUMP.........................................................................................120 BOOM................................................................................................121 ARM.................................................................................................122 SHOVEL CYLINDERS........................................................................................123 RAISING CYLINDER....................................................................................123 DUMPING CYLINDER....................................................................................123 4 IN 1 BUCKET.......................................................................................124 BACKHOE CYLINDERS.......................................................................................125 BOOM CYLINDER.......................................................................................125 ARM.................................................................................................125 BUCKET CYLINDER.....................................................................................126 OUTRIGGER CYLINDER..................................................................................126 BOOM SWING CYLINDER.................................................................................127 JIG ARM CYLINDER....................................................................................127 AIR-CONDITIONING UNIT...................................................................................129 OPERATION OF THE AIR CONDITIONING UNIT..................................................................130 FUSE AND RELAY CENTRE...................................................................................131 DRIVER SEAT WIRING......................................................................................132 SWITCH PANEL WIRING.....................................................................................133 FRONT DASH WIRING.......................................................................................134 LATERAL DASH WIRING.....................................................................................135 ROOF WIRING.............................................................................................136 ENGINE WIRING...........................................................................................137 SPEED SELECTOR WIRING...................................................................................138 BACKHOE WIRING..........................................................................................139 JIG ARM WIRING..........................................................................................140 4WS PUSH-BUTTONS PANEL WIRING...........................................................................141 4WD SOLENOID VALVES WIRING..............................................................................142 WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)...................................................143 20 TESTING AND ADJUSTMENTS..................................................................................145 NORMAL OR STANDARD TECHNICAL DATA.......................................................................147 SPECIAL TOOLS...........................................................................................162 ADJUSTING VALVE CLEARANCE...............................................................................163 ENGINE SPEED TESTS......................................................................................164 TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT.........................................................166 BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE..............................................167 ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER................................................169 ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...................................................................171 BRAKING SYSTEM CHECKS...................................................................................172 PARKING BRAKE ADJUSTMENT................................................................................175 CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT......................................177 CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES................................................179 SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES..................................................183 CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE. ADJUSTING THE LS VALVE.............................185 CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY PRESSURE....................................................187 ADJUSTING THE PC VALVE..................................................................................188 TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....................................................189 CHECKING FOR LEAKS IN THE STEERING CYLINDERS............................................................190 TESTING PRESSURES IN THE POWER TRAIN GROUP..............................................................191 TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES..............................................193 ANALYSIS OF CAUSES HYDRAULIC DRIFT......................................................................194 FRONT EQUIPMENT.....................................................................................194 BACKHOE.............................................................................................196 TESTING THE AIR-CONDITIONING UNIT.......................................................................199 EMPTYING THE AIR-CONDITIONING UNIT......................................................................201 TROUBLESHOOTING.........................................................................................202 FRONT AXLE TROUBLESHOOTING..........................................................................202 FRONT AXLE CHECKING AND TROUBLESHOOTING.............................................................205 REAR AXLE TROUBLESHOOTING...........................................................................207 REAR AXLE CHECKING AND TROUBLESHOOTING..............................................................210 TRANSMISSION TROUBLESHOOTING........................................................................212 30 REMOVAL AND INSTALLATION.................................................................................215 HOW TO READ THE MANUAL..................................................................................217 PRECAUTIONS TO BE TAKEN WHILE WORKING...................................................................218 SPECIAL TOOLS...........................................................................................219 ENGINE HOOD.............................................................................................223 Removal.............................................................................................223 Installation........................................................................................224 FRONT GUARD.............................................................................................225 Removal.............................................................................................225 Installation........................................................................................225 RADIATOR GROUP..........................................................................................226 Removal.............................................................................................226 Installation........................................................................................229 CONDENSER...............................................................................................230 (For machines equipped with an air-conditioning unit)...................................................230 Removal.............................................................................................230 Installation........................................................................................230 MUFFLER.................................................................................................231 Removal.............................................................................................231 Installation........................................................................................231 AIR FILTER..............................................................................................232 Removal.............................................................................................232 Installation........................................................................................232 TURBOCHARGER............................................................................................233 Removal.............................................................................................233 Installation........................................................................................234 AIR-CONDITIONING UNIT COMPRESSOR........................................................................235 Removal.............................................................................................235 Installation........................................................................................236 AIR-CONDITIONING UNIT COMPRESSOR BELT...................................................................237 Removal.............................................................................................237 Installation........................................................................................238 EXHAUST PIPE............................................................................................239 Removal.............................................................................................239 Installation........................................................................................239 FAN AND HEATING GROUP...................................................................................240 Removal.............................................................................................240 Installation........................................................................................245 BATTERY.................................................................................................246 Removal.............................................................................................246 Installation........................................................................................247 FUEL TANK...............................................................................................248 Removal.............................................................................................248 Installation........................................................................................249 STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....250 Removal.............................................................................................250 Installation........................................................................................251 WORKING BRAKE PUMP GROUP................................................................................252 Removal.............................................................................................252 Installation........................................................................................254 STEERING UNIT...........................................................................................255 Removal.............................................................................................255 Installation........................................................................................256 CAB.....................................................................................................257 Removal.............................................................................................257 Installation........................................................................................263 HYDRAULIC OIL TANK......................................................................................265 Removal.............................................................................................265 Installation........................................................................................271 PISTON PUMP.............................................................................................272 Removal.............................................................................................272 Installation........................................................................................273 TRANSMISSION............................................................................................274 Removal.............................................................................................274 Installation........................................................................................278 Disassembly and assembly............................................................................279 CONVERTOR...............................................................................................387 Removal.............................................................................................387 Installation........................................................................................387 ENGINE..................................................................................................388 Removal.............................................................................................388 Installation........................................................................................392 CONTROL VALVE...........................................................................................393 Removal.............................................................................................393 Installation........................................................................................395 STEERING SOLENOID VALVE GROUP...........................................................................396 Removal.............................................................................................396 Installation........................................................................................396 FRONT AXLE..............................................................................................397 Disassembly and assembly............................................................................401 Removal.............................................................................................397 Installation........................................................................................399 REAR AXLE...............................................................................................445 Removal.............................................................................................445 Installation........................................................................................447 Disassembly and assembly............................................................................448 SHOVEL PPC VALVE........................................................................................509 Removal.............................................................................................509 Installation........................................................................................510 SHOVEL LIFT CYLINDERS...................................................................................511 Removal.............................................................................................511 Installation........................................................................................512 SHOVEL DUMP CYLINDERS...................................................................................513 Removal.............................................................................................513 Installation........................................................................................514 SHOVEL..................................................................................................515 Removal.............................................................................................515 Installation........................................................................................515 FRONT WORKING EQUIPMENT.................................................................................516 Removal.............................................................................................516 Installation........................................................................................517 BACKHOE PPC VALVES......................................................................................518 Removal.............................................................................................518 Installation........................................................................................519 PPC VALVE SUPPORT RELEASE CABLES........................................................................520 Removal.............................................................................................520 Installation and adjusting..........................................................................522 PPC VALVE SUPPORT RETURN GAS SPRING.....................................................................523 Removal.............................................................................................523 Installation........................................................................................524 SOLENOID VALVE GROUP (servocontrol and optional attachment).............................................525 Removal.............................................................................................525 Installation........................................................................................526 BACKHOE BOOM CYLINDER...................................................................................527 Removal.............................................................................................527 Installation........................................................................................529 ARM CYLINDER............................................................................................530 Removal.............................................................................................530 Installation........................................................................................531 JIG ARM CYLINDER........................................................................................532 Removal.............................................................................................532 Installation........................................................................................532 OUTRIGGER CYLINDER......................................................................................533 Removal.............................................................................................533 Installation........................................................................................534 BACKHOE SWING CYLINDERS.................................................................................535 Removal.............................................................................................535 Installation........................................................................................537 BACKHOE BUCKET CYLINDER.................................................................................538 Removal.............................................................................................538 Installation........................................................................................539 BACKHOE BOOM SAFETY CYLINDER............................................................................540 Removal.............................................................................................540 Installation........................................................................................541 CYLINDER................................................................................................542 SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS...................................................542 Disassembly.....................................................................................542 Assembly........................................................................................544 BACKHOE SWING CYLINDERS.............................................................................547 Disassembly.....................................................................................547 Assembly........................................................................................550 BACKHOE WORKING EQUIPMENT...............................................................................553 Removal.............................................................................................553 Installation........................................................................................554 BACKHOE BUCKET..........................................................................................555 Removal.............................................................................................555 Installation........................................................................................555 BACKHOE BOOM CYLINDER...................................................................................556 Removal.............................................................................................556 Installation........................................................................................556 ARM.....................................................................................................557 Removal.............................................................................................557 Installation........................................................................................557 JIG ARM.................................................................................................558 Removal.............................................................................................558 Installation........................................................................................558 2nd ARM.................................................................................................559 Removal.............................................................................................559 Installation........................................................................................559 2nd ARM GUIDES..........................................................................................560 Removal.............................................................................................560 Installation........................................................................................560 BACKHOE SWING BRACKET...................................................................................561 Removal.............................................................................................561 Installation........................................................................................561 COMPLETE BACKHOE BACKFRAME..............................................................................562 Removal.............................................................................................562 Installation........................................................................................563 BACKFRAME LOCK PISTONS..................................................................................564 Removal.............................................................................................564 Installation........................................................................................565 40 STANDARD MAINTENANCE.....................................................................................567 TRANSMISSION............................................................................................568 FRONT AXLE..............................................................................................571 REAR AXLE...............................................................................................574 HYDRAULIC PUMP..........................................................................................578 CONTROL VALVE...........................................................................................580 8-SPOOL VERSION.....................................................................................580 10-SPOOL VERSION....................................................................................588 PPC VALVES..............................................................................................596 SHOVEL CONTROL......................................................................................596 SHOVEL CYLINDERS........................................................................................598 DUMP CYLINDER.......................................................................................598 RAISE CYLINDER......................................................................................598 4 IN 1 BUCKET.......................................................................................599 BACKHOE CYLINDERS.......................................................................................600 BOOM................................................................................................600 ARM.................................................................................................600 BUCKET..............................................................................................600 BOOM SWING..........................................................................................601 OUTRIGGERS..........................................................................................602 JIG ARM.............................................................................................602 FRONT WORKING EQUIPMENT.................................................................................604 SWING BRACKET...........................................................................................606 BACKHOE WORKING EQUIPMENT...............................................................................608 90 OTHER....................................................................................................611 ELECTRICAL DIAGRAM (STANDARD VERSION)...................................................................613
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