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Komatsu WH609-WH716 Telescopic Handler Shop Manual – PDF DOWNLOAD
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Komatsu WH609-WH716 Telescopic Handler Shop Manual
- MODEL SERIAL NUMBER
- WH609-1 395F60001 andup
- WH818-1 395F00003 and up
- WH713-1 395F70001 andup
- WH714-1 395F70002 andup
- WH714H-1 395F70003 andup
- WH716-1 395F70004 and up
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Description
Komatsu WH609-WH716 Telescopic Handler Shop Manual
FILE DETAILS:
Komatsu WH609-WH716 Telescopic Handler Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : WEBM005700
Total Pages : 516
KOMATSU WH609-WH716 TELESCOPIC HANDLER SHOP MANUAL – PDF DOWNLOAD:
DESCRIPTION:
Komatsu WH609-WH716 Telescopic Handler 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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
TABLE OF CONTENTS:
Komatsu WH609-WH716 Telescopic Handler Shop Manual
CONTENTS......................................................................................... 3 REVISED PAGES.................................................................................... 5 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................................................................................ 85 CYLINDERS.................................................................................... 92 AIR CONDITIONING SYSTEM...................................................................... 99 CLIMATE CONTROL SYSTEM OPERATION.............................................................100 ELECTRICAL DIAGRAMS..........................................................................101 FUSE CENTRE..............................................................................101 CAB WIRING (1/2).........................................................................102 CAB WIRING (2/2).........................................................................103 CAB WIRING DIAGRAM (see also Group 90)...................................................104 CAB ROOF WIRING..........................................................................105 CAB ROOF WIRING DIAGRAM..................................................................106 ENGINE WIRING............................................................................107 ENGINE WIRING DIAGRAM....................................................................108 FRONT WIRING.............................................................................109 FRONT WIRING DIAGRAM.....................................................................110 REAR FRAME WIRING........................................................................111 REAR FRAME WIRING DIAGRAM................................................................112 FRONT SERVICE LIGHTS WIRING..............................................................113 GROUND WIRING............................................................................114 20 TESTING AND ADJUSTMENTS.......................................................................115 STANDARD SPECIFICATIONS......................................................................117 . ASPIRATED ENGINES......................................................................117 . TURBO ENGINES..........................................................................118 . MACHINE MODELS WH609 - WH613 WITH ASPIRATED ENGINE.....................................119 . MACHINE MODELS WH609 - WH613 WITH TURBO ENGINE.........................................120 . MACHINE MODELS WH713 - WH714 - WH714H - WH716..........................................121 . MACHINE MODEL WH609-1..................................................................122 . MACHINE MODEL WH613-1..................................................................127 . MACHINE MODEL WH713-1..................................................................132 . MACHINE MODEL WH714-1..................................................................137 . MACHINE MODEL WH714H-1.................................................................142 . MACHINE MODEL WH716-1..................................................................147 INTRODUCTION.................................................................................154 VALVE LASH ADJUSTMENT........................................................................155 CHECKING ENGINE SPEED........................................................................156 . CHECKING THE ENGINE WITH NO LOAD.......................................................156 . CHECKING THE ENGINE UNDER LOAD.........................................................157 . ANALYSIS...............................................................................158 TENSIONING THE AIR CONDITIONER COMPRESSOR BELT...............................................159 ADJUSTING ACCELERATOR CABLE LENGTH...........................................................160 ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING THE STOP LAMP MICROSWITCHES.....................161 . Checking procedure.....................................................................161 . Pedal height adjustment................................................................161 . Sprag length adjustment................................................................162 . Microswitch adjustment.................................................................162 ADJUSTING THE PARKING BRAKES.................................................................163 . Brake cable length adjustment..........................................................163 . Functional check.......................................................................164 BLEEDING AIR FROM CIRCUITS...................................................................165 . Pump housing fill......................................................................165 . Bleeding air from cylinders............................................................165 . Bleeding air from brake circuits.......................................................166 PREPARING THE MACHINE READY FOR HYDRAULIC PRESSURE CHECK AND CALIBRATION.....................167 CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC PRESSURES..................................168 FOREWORD.................................................................................168 1. CALIBRATION CHECK GENERAL VALVE (Cut-off valve).......................................169 2. SECONDARY VALVE CALIBRATION CHECK.....................................................169 . Boom lift and extension............................................................169 . Equipment dump and curl............................................................170 3. GENERAL AND SECONDARY VALVE CALIBRATION...............................................171 4. SERVOCONTROL PRESSURE CHECK...........................................................172 5. CHECKING STEERING PRESSURE AND PRIORITY VALVE OPERATION...............................172 . LS signal check....................................................................172 . Inspection of priority valve operation.............................................173 CALIBRATING THE PRESSURE OF THE STEERING SYSTEM..............................................174 . Checking procedure.....................................................................174 . Calibration procedure..................................................................174 INSPECTING THE OPERATION OF THE UNLOADING VALVE..............................................175 CHECKING AND CALIBRATING THE DR VALVE (PUMP FLOW VARIATION)..................................176 . Checking procedure.....................................................................176 . Calibration procedure..................................................................176 CHECKING THE DYNAMIC PUMP DP VALUE...........................................................177 CHECKING PUMP FLOW...........................................................................178 BRAKE SYSTEM CHECKS..........................................................................179 . Inspecting the circuit and brake pumps for leaks.......................................179 . Inspecting the brake units for leaks...................................................179 TRANSMISSION (POWER SHIFT) CHECKS............................................................182 TROUBLESHOOTING GUIDE....................................................................183 . Low clutch pressure................................................................183 . Low feed pressure..................................................................183 . Overtemperature....................................................................183 . Noisy converter....................................................................183 . Poor power.........................................................................183 TRANSMISSION ASSEMBLY PRESSURE CHECKS........................................................184 1. General converter pressure............................................................184 2. Engagement pressure for each individual clutch........................................184 3. Inspecting the 1st clutch - forward and reverse gear..................................185 4. Inspecting the 2nd - 3rd - 4th clutch.................................................185 5. Transmission clutch wear inspection...................................................186 CHECKING THE SPEED OF THE TRANSMISSION SHAFTS RESPONSIBLE FOR TRANSLATION (CARDAN SHAFTS)....187 LEVEL CALIBRATION............................................................................188 CHECKING LOAD CELL CALIBRATION...............................................................189 1. Checking load signal with no load.....................................................189 2. Checking load signal in turnover conditions...........................................189 CALIBRATING THE OVERTURN PREVENTION SYSTEM (SAR).............................................190 . Calibration conditions:................................................................190 . Calibration procedure..................................................................190 . Error coding...........................................................................193 CHECKING WEIGHT PERCENTAGE ON REAR AXLE......................................................195 . Preparing the machine ready for the inspection.........................................195 CHECKING SHOE CLEARANCE......................................................................197 1. Intermediate boom front shoe clearance................................................197 CHECKING BOOM SIDE ALIGNMENT.................................................................199 BOOM CHAINS..................................................................................201 . Oxidation inspection...................................................................201 . Chain re-lubrication procedure.........................................................202 CHAIN TENSIONING.............................................................................203 . Preparation............................................................................203 1. Retraction chains:....................................................................204 . Checking procedure.................................................................204 . Adjustment procedure...............................................................204 2. Extension chains......................................................................205 . Checking procedure.................................................................205 . Adjustment procedure...............................................................206 3. Checking chain stretch................................................................206 4. Final checks..........................................................................207 CHECKING FOR BLOW-BY.........................................................................208 ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT.......................................211 1. Checking procedure for stabilizers (if equipped)......................................211 2. Checking procedure for equipment cylinder.............................................213 3. Checking procedure for the boom lift cylinder.........................................214 4. Checking procedure for the boom extension cylinder....................................216 5. Checking procedure for the frame levelling cylinder...................................217 6. Checking procedure for axle locking cylinder..........................................218 EQUALIZING STABILIZER SPEED..................................................................220 AIR CONDITIONING SYSTEM MAINTENANCE..........................................................221 . Emptying and filling the air conditioning system.......................................221 CHECKING THE A/C SYSTEM’S OPERATING TEMPERATURE..............................................222 . Checking the A/C system................................................................222 30 REMOVAL AND INSTALLATION......................................................................225 HOW TO READ THE MANUAL.......................................................................229 PRECAUTIONS TO BE TAKEN WHEN WORKING.........................................................230 SPECIAL TOOLS................................................................................231 ENGINE HOOD..................................................................................239 Removal..................................................................................239 Installation.............................................................................240 AIR FILTER...................................................................................241 Removal..................................................................................241 Installation.............................................................................241 TURBOCOMPRESSOR (only if equipped)...........................................................242 Removal..................................................................................242 Installation.............................................................................243 EXHAUST PIPE.................................................................................244 Removal..................................................................................244 . 1st Length.............................................................................244 . 2nd Length.............................................................................244 Installation.............................................................................245 GENERATOR - FAN BELT.........................................................................246 Removal..................................................................................246 Installation.............................................................................247 RADIATOR-EXCHANGER ASSEMBLY..................................................................248 Removal..................................................................................248 Installation.............................................................................250 MUFFLER......................................................................................251 Removal..................................................................................251 Installation.............................................................................251 BATTERY - BATTERY TRAY.......................................................................252 Removal..................................................................................252 . Battery................................................................................252 . Battery tray...........................................................................252 Installation.............................................................................253 CYLINDER HEAD................................................................................254 Removal..................................................................................254 Installation.............................................................................255 INJECTORS....................................................................................256 Removal..................................................................................256 Installation.............................................................................256 INJECTION PUMP...............................................................................257 Removal..................................................................................257 Installation.............................................................................257 HYDRAULIC PUMP...............................................................................258 Removal..................................................................................258 Installation.............................................................................259 COMPLETE ENGINE- SHIFT ASSEMBLY..............................................................260 Removal..................................................................................260 Installation.............................................................................269 ENGINE-TRANSMISSION..........................................................................270 Detachment...............................................................................270 Joining..................................................................................271 CONTROL VALVE ASSEMBLY.......................................................................272 Removal..................................................................................272 Installation.............................................................................275 BRACKET CONTROL, EQUIPMENT LOCK, AND FRAME LEVELLING SOLENOID VALVES.........................276 Removal..................................................................................276 Installation.............................................................................276 AIR CONDITIONER COMPRESSOR (only if equipped)................................................277 Removal..................................................................................277 Installation.............................................................................278 AIR CONDITIONER COMPRESSOR BELT..............................................................279 Removal..................................................................................279 Installation.............................................................................280 SERVO-CONTROL FEED VALVE.....................................................................281 Removal..................................................................................281 Installation.............................................................................281 STEERING SELECTION SOLENOID VALVE ASSEMBLY...................................................282 Removal..................................................................................282 Installation.............................................................................282 FRONT AXLE...................................................................................283 Preparation..............................................................................283 . Machine with outriggers............................................................283 . Machine without outriggers.........................................................283 Removal..............................................................................283 Installation.........................................................................285 REAR AXLE....................................................................................286 Preparation..............................................................................286 . Machine with outriggers............................................................286 . Machine without outriggers.........................................................286 Removal..............................................................................286 Installation.........................................................................288 TELESCOPIC BOOM..............................................................................289 Removal..................................................................................289 Installation.............................................................................291 LIFT AND OFFSET CYLINDERS....................................................................296 Removal..................................................................................296 Installation.............................................................................297 INTERMEDIATE AND TOP BOOM....................................................................298 Removal..................................................................................298 Installation.............................................................................302 EXTENSION CYLINDER...........................................................................303 Removal..................................................................................303 Installation.............................................................................304 BOOM SLIDING SHOES...........................................................................305 Replacement..............................................................................305 1. Lower shoes for intermediate and top booms........................................305 2. Upper shoes for intermediate boom.................................................306 3. Side shoes for intermediate and top boom..........................................307 4. Upper shoes for top boom..........................................................307 5. Rear upper shoes for intermediate boom............................................309 6. Rear upper shoes for top boom.....................................................310 7. Rear lower shoes for intermediate and top boom....................................311 EXTENSION AND RETRACTION CHAINS (Versions with 3-section boom)...............................314 Removal..................................................................................314 Installation.............................................................................316 CHAIN RETURN PULLEY PINS AND BUSHINGS........................................................317 RETRACTION CHAIN PULLEY..................................................................317 Removal..............................................................................317 Installation.........................................................................318 EXTENSION CHAIN PULLEYS..................................................................319 Removal..............................................................................319 Installation.........................................................................320 LOAD CELL....................................................................................321 Installation.............................................................................321 CONTROL UNIT.................................................................................324 Removal..................................................................................324 Installation.............................................................................324 BALLAST......................................................................................325 Removal..................................................................................325 Installation.............................................................................325 ENGINE LINE CENTRE...........................................................................326 Removal..................................................................................326 Installation.............................................................................326 ACCELERATOR CABLE............................................................................327 Removal..................................................................................327 Installation.............................................................................328 SHIFT-REVERSING GEAR LEVER ASSEMBLY..........................................................329 Removal..................................................................................329 Installation.............................................................................329 STEERING COLUMN SWITCH UNIT - DIPSWITCH......................................................330 Removal..................................................................................330 Installation.............................................................................330 STEERING UNIT................................................................................331 Removal..................................................................................331 Installation.............................................................................333 Disassembly..............................................................................334 . Removing the seals.................................................................336 . Removing the wiper ring............................................................336 Assembly.................................................................................337 . Installing the inner seal (15).....................................................337 . Installing the control valve.......................................................337 . Completing the installation procedure..............................................338 STEERING COLUMN..............................................................................341 Removal..................................................................................341 Installation.............................................................................341 BRAKE PUMPS..................................................................................342 Removal..................................................................................342 Installation.............................................................................343 PPC VALVE....................................................................................344 Removal..................................................................................344 Installation.............................................................................345 LEVEL........................................................................................346 Removal..................................................................................346 Installation.............................................................................346 WIPER MOTORS.................................................................................347 Removal..................................................................................347 . Front wiper motor......................................................................347 . Rear wiper motor.......................................................................348 . Upper wiper motor......................................................................349 Installation.............................................................................349 PARKING BRAKE CABLE..........................................................................350 Removal..................................................................................350 Installation.............................................................................351 DASH / INSTRUMENT PANEL......................................................................352 Removal..................................................................................352 Installation.............................................................................352 CONTROL PANEL................................................................................353 Removal..................................................................................353 Installation.............................................................................353 FUSE AND RELAY CENTRE........................................................................354 Removal..................................................................................354 Installation.............................................................................354 PROPELLER SHAFT..............................................................................355 Removal..................................................................................355 . Front cardan shaft.....................................................................355 . Rear cardan shaft......................................................................355 Installation.............................................................................356 FUEL TANK....................................................................................357 Removal..................................................................................357 Installation.............................................................................358 HYDRAULIC OIL TANK...........................................................................359 Removal..................................................................................359 Installation.............................................................................360 FRAME LEVELLING CYLINDER.....................................................................361 Removal..................................................................................361 Installation.............................................................................361 FRAME SWING LOCKING ROD (WH609 and WH613 only)...............................................362 Removal..................................................................................362 Installation.............................................................................362 AXLE LOCKING CYLINDER........................................................................363 Removal..................................................................................363 Installation.............................................................................363 STABILIZER CYLINDERS (If equipped)...........................................................364 Removal..................................................................................364 Installation.............................................................................365 EQUIPMENT HOLDER.............................................................................367 Removal..................................................................................367 Installation.............................................................................368 EQUIPMENT MOTION CYLINDER....................................................................369 Removal..................................................................................369 Installation.............................................................................370 CYLINDERS....................................................................................371 Disassembly..............................................................................371 Assembly.................................................................................372 EQUIPMENT QUICK-LOCK ASSEMBLY................................................................376 Removal..................................................................................376 Installation.............................................................................376 AIR CONDITIONER FANS.........................................................................377 Removal..................................................................................377 Installation.............................................................................377 AIR CONDITIONER CONDENSER ASSEMBLY...........................................................378 Removal..................................................................................378 Installation.............................................................................379 DEHUMIDIFYING FILTER.........................................................................380 Removal..................................................................................380 Installation.............................................................................381 PAIR CONDITIONING SYSTEM PRESSURE SWITCH.....................................................382 Removal..................................................................................382 Installation.............................................................................382 CAB..........................................................................................383 Removal..................................................................................383 Installation.............................................................................387 TRANSMISSION.................................................................................388 TRANSMISSION ASSEMBLY....................................................................388 Disassembly..............................................................................388 Assembly.................................................................................399 1st CLUTCH...............................................................................400 Disassembly..............................................................................400 Assembly.................................................................................403 2nd CLUTCH...............................................................................404 Disassembly..............................................................................404 Assembly.................................................................................408 4th CLUTCH...............................................................................409 Disassembly..............................................................................409 Assembly.................................................................................412 3rd CLUTCH...............................................................................413 Disassembly..............................................................................413 Assembly.................................................................................416 REVERSE CLUTCH...........................................................................417 Disassembly..............................................................................417 Assembly.................................................................................419 FORWARD CLUTCH...........................................................................421 Disassembly..............................................................................421 Assembly.................................................................................424 PRESSURE REGULATOR VALVE.................................................................425 Disassembly..............................................................................425 Assembly.................................................................................425 MODULATED VALVE..........................................................................426 Disassembly..............................................................................426 Assembly.................................................................................427 SPACER PLATE.............................................................................430 Disassembly..............................................................................430 Assembly.................................................................................434 CONVERTER HOUSING........................................................................435 Disassembly..............................................................................435 Assembly.................................................................................437 DROP BOX ASSEMBLY........................................................................438 Disassembly..............................................................................438 . Complete drop box assembly.........................................................438 . Input shaft........................................................................440 Assembly.................................................................................440 . Input shaft........................................................................440 . Complete drop box assembly.........................................................440 AXLES........................................................................................449 Disassembly..............................................................................449 . Planetary reduction................................................................449 . Steering case......................................................................453 . Cardan shaft.......................................................................456 . Brakes.............................................................................458 . Parking brake assembly (front axle)................................................460 . Removal of steering cylinder.......................................................462 . Disassembly of steering cylinder...................................................464 . Differential.......................................................................465 . Bevel pinion.......................................................................470 ASSEMBLY.................................................................................473 . Bevel pinion.......................................................................473 . Differential.......................................................................481 . Steering cylinder..................................................................487 . Steering cylinder..................................................................490 . Convergency adjustment.............................................................493 . Parking brake assembly (front axle)................................................493 . Brakes.............................................................................495 . Cardan shaft.......................................................................498 . Steering case......................................................................499 . Planetary reduction................................................................501 90 OTHERS........................................................................................509 CAB WIRING...................................................................................511 ELECTRICAL DIAGRAM...........................................................................513
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