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KOMATSU WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 TELESCOPIC HANDLER SHOP MANUAL WEBM008500 – PDF DOWNLOAD
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KOMATSU WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 TELESCOPIC HANDLER SHOP MANUAL WEBM008500 – PDF DOWNLOAD
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Description
KOMATSU WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 TELESCOPIC HANDLER SHOP MANUAL WEBM008500 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 TELESCOPIC HANDLER SHOP MANUAL WEBM008500 – PDF DOWNLOAD
Language : English
Pages : 496
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 TELESCOPIC HANDLER SHOP MANUAL WEBM008500 – PDF DOWNLOAD
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 ENGINE-TRANSMISSION COUPLING................................................................. 28 POWER TRAIN.................................................................................. 29 TRANSMISSION................................................................................. 31 FRONT AXLE................................................................................... 57 REAR AXLE.................................................................................... 61 BRAKE PUMPS.................................................................................. 65 STEERING SYSTEM (4WS)........................................................................ 66 STEERING UNIT................................................................................ 70 HYDRAULIC DIAGRAM............................................................................ 71 HYDRAULIC PUMP............................................................................... 72 CONTROL VALVE................................................................................ 76 PPC VALVE.................................................................................... 77 SOLENOID VALVES.............................................................................. 80 SAFETY VALVES................................................................................ 86 CYLINDERS.................................................................................... 93 AIR CONDITIONING SYSTEM......................................................................100 CLIMATE CONTROL SYSTEM OPERATION.............................................................101 20 TESTING AND ADJUSTMENTS.......................................................................103 STANDARD SPECIFICATIONS......................................................................105 INTRODUCTION.................................................................................135 VALVE LASH ADJUSTMENT........................................................................137 CHECKING ENGINE SPEED........................................................................138 TENSIONING THE AIR CONDITIONER COMPRESSOR BELT...............................................141 ADJUSTING ACCELERATOR CABLE LENGTH...........................................................142 ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING THE STOP LAMP MICROSWITCHES.....................143 ADJUSTING THE PARKING BRAKES.................................................................145 BLEEDING AIR FROM CIRCUITS...................................................................147 PREPARING THE MACHINE READY FOR HYDRAULIC PRESSURE CHECK AND CALIBRATION.....................149 CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC PRESSURES..................................150 CALIBRATING THE PRESSURE OF THE STEERING SYSTEM..............................................156 INSPECTING THE OPERATION OF THE UNLOADING VALVE..............................................157 CHECKING AND CALIBRATING THE DR VALVE (PUMP FLOW VARIATION)..................................158 CHECKING THE DYNAMIC PUMP DP VALUE...........................................................159 CHECKING PUMP FLOW...........................................................................160 BRAKE SYSTEM CHECKS..........................................................................161 TRANSMISSION (POWER SHIFT) CHECKS............................................................164 TRANSMISSION ASSEMBLY PRESSURE CHECKS........................................................166 CHECKING THE SPEED OF THE TRANSMISSION SHAFTS RESPONSIBLE FOR TRANSLATION (CARDAN SHAFTS)....169 LEVEL CALIBRATION............................................................................170 CHECKING LOAD CELL CALIBRATION...............................................................171 CALIBRATING THE OVERTURN PREVENTION SYSTEM (STANDARD)........................................172 CALIBRATING THE OVERTURN PREVENTION (ASM) CONTROL UNIT.......................................177 CHECKING LED CALIBRATION (version with ASM)..................................................179 CHECKING SLIDING PADS CLEARANCE..............................................................180 CHECKING BOOM SIDE ALIGNMENT.................................................................182 BOOM CHAINS..................................................................................184 CHAIN TENSIONING.............................................................................186 CHECKING FOR BLOW-BY.........................................................................191 ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT.......................................194 EQUALIZING STABILIZER SPEED..................................................................203 AIR CONDITIONING SYSTEM MAINTENANCE..........................................................204 CHECKING THE A/C SYSTEM’S OPERATING TEMPERATURE..............................................205 30 REMOVAL AND INSTALLATION......................................................................207 HOW TO READ THE MANUAL.......................................................................211 PRECAUTIONS TO BE TAKEN WHEN WORKING.........................................................212 SPECIAL TOOLS................................................................................213 ENGINE HOOD..................................................................................221 Removal..................................................................................221 Installation.............................................................................222 RADIATOR HOOD................................................................................223 Removal..................................................................................223 Installation.............................................................................223 AIR FILTER...................................................................................224 Removal..................................................................................224 Installation.............................................................................224 TURBOCOMPRESSOR..............................................................................225 Removal..................................................................................225 Installation.............................................................................226 EXHAUST PIPE.................................................................................227 Removal..................................................................................227 . 1st Length.............................................................................227 . 2nd Length.............................................................................227 Installation.............................................................................228 BELT, FAN....................................................................................229 Removal..................................................................................229 Installation.............................................................................230 RADIATOR-EXCHANGER ASSEMBLY..................................................................231 Removal..................................................................................231 Installation.............................................................................233 INTERCOOLER..................................................................................234 Removal..................................................................................234 Installation.............................................................................236 MUFFLER......................................................................................237 Removal..................................................................................237 Installation.............................................................................237 BATTERY - BATTERY TRAY.......................................................................238 Removal..................................................................................238 . Battery................................................................................238 . Battery tray...........................................................................238 Installation.............................................................................239 CYLINDER HEAD................................................................................240 Removal..................................................................................240 Installation.............................................................................241 INJECTORS....................................................................................242 Removal..................................................................................242 Installation.............................................................................242 INJECTION PUMP...............................................................................243 Removal..................................................................................243 Installation.............................................................................243 HYDRAULIC PUMP...............................................................................244 Removal..................................................................................244 Installation.............................................................................245 COMPLETE ENGINE- SHIFT ASSEMBLY..............................................................246 Removal..................................................................................246 Installation.............................................................................255 ENGINE-TRANSMISSION..........................................................................256 Detachment...............................................................................256 Joining..................................................................................257 CONTROL VALVE ASSEMBLY.......................................................................258 Removal..................................................................................258 Installation.............................................................................261 BRACKET CONTROL, EQUIPMENT LOCK, AND FRAME LEVELLING SOLENOID VALVES.........................262 Removal..................................................................................262 Installation.............................................................................262 AIR CONDITIONER COMPRESSOR (only if equipped)................................................263 Removal..................................................................................263 Installation.............................................................................264 COMPRESSOR BELT..............................................................................265 Removal..................................................................................265 Installation.............................................................................267 SERVO-CONTROL FEED VALVE.....................................................................268 Removal..................................................................................268 Installation.............................................................................268 STEERING SELECTION SOLENOID VALVE ASSEMBLY...................................................269 Removal..................................................................................269 Installation.............................................................................269 FRONT AXLE...................................................................................270 Preparation..............................................................................270 . Machine with outriggers............................................................270 . Machine without outriggers.........................................................270 Removal..............................................................................270 Installation.........................................................................272 REAR AXLE....................................................................................273 Preparation..............................................................................273 . Machine with outriggers............................................................273 . Machine without outriggers.........................................................273 Removal..............................................................................273 Installation.........................................................................275 TELESCOPIC BOOM..............................................................................276 Removal..................................................................................276 Installation.............................................................................279 LIFT AND OFFSET CYLINDERS....................................................................283 Removal..................................................................................283 Installation.............................................................................284 INTERMEDIATE AND TOP BOOM....................................................................285 Removal..................................................................................285 Installation.............................................................................289 EXTENSION CYLINDER...........................................................................290 Removal..................................................................................290 Installation.............................................................................291 BOOM SLIDING PADS............................................................................292 Replacement..............................................................................292 1. Lower sliding pads for intermediate and top booms.................................292 2. Upper sliding pads for intermediate boom..........................................293 3. Side sliding pads for intermediate and top boom...................................294 4. Upper sliding pads for top boom...................................................294 5. Rear upper sliding pads for intermediate boom.....................................296 6. Rear upper sliding pads for top boom..............................................297 7. Rear lower sliding pads for intermediate and top boom.............................298 EXTENSION AND RETRACTION CHAINS (Versions with 3-section boom)...............................301 Removal..................................................................................301 Installation.............................................................................303 CHAIN RETURN PULLEY PINS AND BUSHINGS........................................................304 RETRACTION CHAIN PULLEY..................................................................304 Removal..............................................................................304 Installation.........................................................................305 EXTENSION CHAIN PULLEYS..................................................................306 Removal..............................................................................306 Installation.........................................................................307 LOAD CELL....................................................................................308 Installation.............................................................................308 CONTROL UNIT.................................................................................311 Removal..................................................................................311 Installation.............................................................................311 BALLAST......................................................................................312 Removal..................................................................................312 Installation.............................................................................312 ENGINE LINE CENTRE...........................................................................313 Removal..................................................................................313 Installation.............................................................................313 ACCELERATOR CABLE............................................................................314 Removal..................................................................................314 Installation.............................................................................315 SHIFT-REVERSING GEAR LEVER ASSEMBLY..........................................................316 Removal..................................................................................316 Installation.............................................................................316 STEERING COLUMN SWITCH UNIT - DIPSWITCH......................................................317 Removal..................................................................................317 Installation.............................................................................317 STEERING UNIT................................................................................318 Removal..................................................................................318 Installation.............................................................................320 Disassembly..............................................................................321 . Removing the seals.................................................................323 . Removing the wiper ring............................................................323 Assembly.................................................................................324 . Installing the inner seal (15).....................................................324 . Installing the control valve.......................................................324 . Completing the installation procedure..............................................325 STEERING COLUMN..............................................................................328 Removal..................................................................................328 Installation.............................................................................328 BRAKE PUMPS..................................................................................329 Removal..................................................................................329 Installation.............................................................................330 PPC VALVE....................................................................................331 Removal..................................................................................331 Installation.............................................................................332 LEVEL........................................................................................333 Removal..................................................................................333 Installation.............................................................................333 WIPER MOTORS.................................................................................334 Removal..................................................................................334 . Front wiper motor......................................................................334 . Rear wiper motor.......................................................................335 . Upper wiper motor......................................................................336 Installation.............................................................................336 PARKING BRAKE CABLE..........................................................................337 Removal..................................................................................337 Installation.............................................................................338 DASH / INSTRUMENT PANEL......................................................................339 Removal..................................................................................339 Installation.............................................................................339 CONTROL PANEL................................................................................340 Removal..................................................................................340 Installation.............................................................................340 FUSE AND RELAY CENTRE........................................................................341 Removal..................................................................................341 Installation.............................................................................341 PROPELLER SHAFT..............................................................................342 Removal..................................................................................342 . Front cardan shaft.....................................................................342 . Rear cardan shaft......................................................................342 Installation.............................................................................343 FUEL TANK....................................................................................344 Removal..................................................................................344 Installation.............................................................................345 HYDRAULIC OIL TANK...........................................................................346 Removal..................................................................................346 Installation.............................................................................347 FRAME LEVELLING CYLINDER.....................................................................348 Removal..................................................................................348 Installation.............................................................................348 FRAME SWING LOCKING ROD (WH609 and WH613 only)...............................................349 Removal..................................................................................349 Installation.............................................................................349 AXLE LOCKING CYLINDER........................................................................350 Removal..................................................................................350 Installation.............................................................................350 STABILIZER CYLINDERS (If equipped)...........................................................351 Removal..................................................................................351 Installation.............................................................................352 EQUIPMENT HOLDER.............................................................................354 Removal..................................................................................354 Installation.............................................................................355 EQUIPMENT MOTION CYLINDER....................................................................356 Removal..................................................................................356 Installation.............................................................................357 CYLINDERS....................................................................................358 Disassembly..............................................................................358 Assembly.................................................................................359 EQUIPMENT QUICK-LOCK ASSEMBLY................................................................363 Removal..................................................................................363 Installation.............................................................................363 AIR CONDITIONER FANS.........................................................................364 Removal..................................................................................364 Installation.............................................................................364 AIR CONDITIONER CONDENSER ASSEMBLY...........................................................365 Removal..................................................................................365 Installation.............................................................................366 DEHUMIDIFYING FILTER.........................................................................367 Removal..................................................................................367 Installation.............................................................................368 AIR CONDITIONING SYSTEM PRESSURE SWITCH......................................................369 Removal..................................................................................369 Installation.............................................................................369 CAB..........................................................................................370 Removal..................................................................................370 Installation.............................................................................374 TRANSMISSION.................................................................................375 TRANSMISSION ASSEMBLY....................................................................375 Disassembly..............................................................................375 Assembly.................................................................................386 1st CLUTCH...............................................................................387 Disassembly..............................................................................387 Assembly.................................................................................390 2nd CLUTCH...............................................................................391 Disassembly..............................................................................391 Assembly.................................................................................395 4th CLUTCH...............................................................................396 Disassembly..............................................................................396 Assembly.................................................................................399 3rd CLUTCH...............................................................................400 Disassembly..............................................................................400 Assembly.................................................................................403 REVERSE CLUTCH...........................................................................404 Disassembly..............................................................................404 Assembly.................................................................................406 FORWARD CLUTCH...........................................................................408 Disassembly..............................................................................408 Assembly.................................................................................411 PRESSURE REGULATOR VALVE.................................................................412 Disassembly..............................................................................412 Assembly.................................................................................412 MODULATED VALVE..........................................................................413 Disassembly..............................................................................413 Assembly.................................................................................414 SPACER PLATE.............................................................................417 Disassembly..............................................................................417 Assembly.................................................................................421 CONVERTER HOUSING........................................................................422 Disassembly..............................................................................422 Assembly.................................................................................424 DROP BOX ASSEMBLY........................................................................425 Disassembly..............................................................................425 . Complete drop box assembly.........................................................425 . Input shaft........................................................................427 Assembly.................................................................................427 . Input shaft........................................................................427 . Complete drop box assembly.........................................................427 AXLES........................................................................................436 Disassembly..............................................................................436 . Planetary reduction................................................................436 . Steering case......................................................................440 . Cardan shaft.......................................................................443 . Brakes.............................................................................445 . Parking brake assembly (front axle)................................................447 . Removal of steering cylinder.......................................................449 . Disassembly of steering cylinder...................................................451 . Differential.......................................................................452 . Bevel pinion.......................................................................457 Assembly.................................................................................460 . Bevel pinion.......................................................................460 . Differential.......................................................................468 . Steering cylinder..................................................................474 . Steering cylinder..................................................................477 . Convergency adjustment.............................................................480 . Parking brake assembly (front axle)................................................480 . Brakes.............................................................................482 . Cardan shaft.......................................................................485 . Steering case......................................................................486 . Planetary reduction................................................................488
DESCRIPTION:
KOMATSU WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 TELESCOPIC HANDLER SHOP MANUAL WEBM008500 – PDF DOWNLOAD
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 ADJUSTING
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.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
S.S 27/12/24
