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KOMATSU XWB97R-8 BACKHOE LOADER SHOP MANUAL WENBM00260 – PDF DOWNLOAD
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KOMATSU XWB97R-8 BACKHOE LOADER SHOP MANUAL WENBM00260 – PDF DOWNLOAD
SERIAL NUMBERS WB97R-8 F60001 and up
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Description
KOMATSU XWB97R-8 BACKHOE LOADER SHOP MANUAL WENBM00260 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU XWB97R-8 BACKHOE LOADER SHOP MANUAL WENBM00260 – PDF DOWNLOAD
Language : English
Pages : 902
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS WB97R-8 F60001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU XWB97R-8 BACKHOE LOADER SHOP MANUAL WENBM00260 – PDF DOWNLOAD
00 INDEX AND FOREWORD......................................................................... 3 INDEX..................................................................................... 4 FOREWORD, SAFETY, BASIC INFORMATION....................................................... 9 HOW TO READ THE SHOP MANUAL........................................................... 9 SAFETY NOTICE FOR OPERATION........................................................... 11 PRECAUTIONS TO PREVENT FIRE........................................................... 19 ACTIONS IF FIRE OCCURS................................................................ 21 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.......................................... 22 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS......................................... 23 PRECAUTIONS FOR DEF................................................................... 24 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.................................... 24 PRECAUTIONS FOR ADDING............................................................ 24 PRECAUTIONS FOR STORING........................................................... 24 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE........................................... 24 THE OTHER PRECAUTIONS............................................................. 24 STORE AdBlue/DEF...................................................................... 25 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.......................................... 26 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS............................... 29 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT......................................... 36 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT........................................ 38 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...................................... 39 PRACTICAL USE OF KOMTRAX.............................................................. 40 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER......................................... 41 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER............. 41 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER............. 42 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER............. 43 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS............................ 45 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR............................. 49 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR..................... 50 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL................... 52 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH................... 53 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE.............. 55 HOW TO READ ELECTRICAL WIRE CODE...................................................... 56 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD......................................... 60 STANDARD TIGHTENING TORQUE TABLE...................................................... 63 CONVERSION TABLE...................................................................... 70 ABBREVIATION LIST..................................................................... 75 01 SPECIFICATIONS............................................................................. 79 CONTENTS.................................................................................. 80 SPECIFICATIONS............................................................................ 81 SPECIFICATION DRAWING................................................................. 81 SPECIFICATION DRAWING: WB97R-8.................................................... 81 SPECIFICATIONS........................................................................ 84 SPECIFICATIONS: WB97R-8........................................................... 84 WEIGHT TABLE.......................................................................... 90 WEIGHT TABLE: WB97R-8............................................................. 90 FUEL, COOLANT, LUBRICANTS............................................................. 92 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................. 92 10 STRUCTURE AND FUNCTION..................................................................... 95 CONTENTS.................................................................................. 96 UREA SCR SYSTEM........................................................................... 98 LAYOUT DRAWING OF UREA SCR SYSTEM..................................................... 98 UREA SCR SYSTEM DIAGRAM...............................................................101 FUNCTION OF UREA SCR SYSTEM...........................................................102 FUNCTION OF DEF SYSTEM............................................................102 INDUCEMENT STRATEGY...............................................................103 COMPONENT PARTS OF UREA SCR SYSTEM....................................................110 KDOC AND DEF MIXING TUBE..........................................................110 SCR ASSEMBLY......................................................................112 DEF TANK..........................................................................114 DEF PUMP..........................................................................116 DEF INJECTOR......................................................................117 DEF HOSE..........................................................................118 DEF TANK HEATING VALVE............................................................119 HYDRAULIC SYSTEM..........................................................................120 LAYOUT DRAWING OF HYDRAULIC SYSTEM....................................................120 CLSS..................................................................................122 STRUCTURE OF CLSS.................................................................122 FUNCTION OF CLSS..................................................................123 COMPONENT PARTS OF HYDRAULIC SYSTEM...................................................125 HYDRAULIC TANK....................................................................125 MAIN PUMP.........................................................................127 CONTROL VALVE.....................................................................140 POWER TRAIN SYSTEM........................................................................170 LAYOUT DRAWING OF POWER TRAIN SYSTEM..................................................170 OPERATION OF POWER TRAIN SYSTEM.......................................................172 COMPONENT PARTS OF POWER TRAIN SYSTEM.................................................173 TRANSMISSION......................................................................173 DRIVE SHAFT.......................................................................183 TRANSMISSION CONTROL VALVE........................................................186 AXLE..............................................................................188 WORK EQUIPMENT SYSTEM.....................................................................198 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...............................................198 LOADER WORK EQUIPMENT PPC VALVE.......................................................201 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION...................201 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION...................203 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION....207 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION....209 BACKHOE PPC VALVE.....................................................................214 STRUCTURE OF LH BACKHOE PPC VALVE.................................................214 STRUCTURE OF RH BACKHOE PPC VALVE.................................................216 OUTRIGGER PPC VALVE...................................................................218 STRUCTURE OF OUTRIGGER PPC VALVE..................................................218 OPERATION OF OUTRIGGER PPC VALVE..................................................219 STEERING UNIT.........................................................................223 BRAKE PUMP............................................................................224 SOLENOID VALVES.......................................................................225 SOLENOID VALVE GROUP..............................................................225 TELESCOPIC ARM SOLENOID VALVE.....................................................226 SIDE DIGGING BOOM SOLENOID VALVE..................................................227 2-ATTACHMENT SOLENOID VALVE.......................................................228 STEERING MODE SOLENOID VALVE......................................................229 HAMMER SOLENOID VALVE.............................................................230 PPC CIRCUIT ACCUMULATOR...............................................................231 SAFETY VALVES.........................................................................232 LOADER ARM SAFETY VALVE...........................................................232 LOADER BUCKET SAFETY VALVE........................................................233 BACKHOE BOOM SAFETY VALVE.........................................................234 BACKHOE ARM SAFETY VALVE..........................................................235 OUTRIGGER SAFETY VALVE............................................................236 WORK EQUIPMENT............................................................................237 STRUCTURE OF LOADER WORK EQUIPMENT....................................................237 STRUCTURE OF BACKHOE WORK EQUIPMENT...................................................238 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM..................................239 20 STANDARD VALUE TABLE.......................................................................241 CONTENTS..................................................................................242 STANDARD VALUE TABLE FOR ENGINE...........................................................243 STANDARD VALUE TABLE FOR ENGINE: WB97R-8..............................................243 STANDARD VALUE TABLE FOR MACHINE..........................................................246 STANDARD VALUE TABLE FOR MACHINE: WB97R-8.............................................246 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE.................................264 30 TESTING AND ADJUSTING......................................................................271 CONTENTS..................................................................................272 ENGINE AND COOLING SYSTEM.................................................................274 TEST ENGINE SPEED.....................................................................274 PREPARATION FOR TESTING ENGINE SPEED..............................................274 TEST ENGINE LOW IDLE SPEED........................................................274 TEST ENGINE HIGH IDLE SPEED.......................................................274 TEST ENGINE LOW IDLE SPEED AT PUMP AT RELIEF......................................275 TEST ENGINE HIGH IDLE SPEED WITH TORQUE CONVERTER AT STALL........................275 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF AND TORQUE CONVERTER AT STALL.....275 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF (FUEL CONTROL DIAL SET)...........276 TEST EXHAUST GAS COLOR................................................................277 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER.....................................277 TEST EXHAUST GAS COLOR BY SMOKE METER.............................................277 STEERING SYSTEM...........................................................................279 CHECK LEAKAGES IN STEERING CYLINDER...................................................279 TEST STEERING CIRCUIT OIL PRESSURE....................................................280 ADJUST TOE-IN/STEERING ANGLE WITH AXLES REMOVED FROM MACHINE..........................281 TOE-IN ADJUSTMENT.................................................................281 ADJUSTMENT WITH REFERENCE STEERING ANGLE..........................................283 ADJUST TOE-IN/STEERING ANGLE WITH AXLES WITHOUT REMOVED FROM MACHINE..................284 STEERING ANGLE CHECKING AND ADJUSTMENT............................................284 BRAKE SYSTEM..............................................................................287 TEST BRAKE SYSTEM PRESSURE............................................................287 TEST BRAKE SYSTEM LEAKAGE.............................................................289 TEST BRAKE PISTON STROKE..............................................................290 BLEED AIR FROM THE BRAKE CIRCUIT......................................................291 TEST BRAKE PUMP BALANCING VALVE.......................................................292 TEST BRAKE PEDAL STROKE...............................................................293 ADJUST BRAKE PEDAL TRAVEL.............................................................294 TEST AND ADJUST PARKING BRAKE SYSTEM..................................................296 TEST PARKING BRAKE................................................................296 ADJUST PARKING BRAKE..............................................................297 HYDRAULIC SYSTEM..........................................................................298 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................................298 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK....................................298 RELEASE REMAINING PRESSURE IN LOADER HYDRAULIC CYLINDER CIRCUIT...................298 RELEASE REMAINING PRESSURE IN BACKHOE HYDRAULIC CYLINDER CIRCUIT..................298 TEST AND ADJUST HYDRAULIC CIRCUIT PRESSURE............................................299 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE...........................................300 TEST AND ADJUST UNLOAD PRESSURE...................................................303 TEST AND ADJUST RELIEF PRESSURE...................................................303 ADJUST MAIN SAFETY VALVE (LS SAFETY VALVE)........................................304 ADJUST SECONDARY VALVE............................................................304 TEST BACKHOE BOOM OVERLOAD SWITCH.................................................305 TEST AND ADJUST CONTROL CIRCUIT OIL PRESSURE..........................................306 TEST CONTROL CIRCUIT OIL PRESSURE.................................................306 ADJUST CONTROL CIRCUIT OIL PRESSURE...............................................306 MEASURE AND ADJUST PUMP PC CONTROL OIL PRESSURE.......................................307 MEASURE PUMP PC CONTROL OIL PRESSURE..............................................307 ADJUST PUMP PC CONTROL OIL PRESSURE...............................................309 MEASURE AND ADJUST PUMP LS CONTROL OIL PRESSURE.......................................311 MEASURE PUMP LS CONTROL OIL PRESSURE..............................................311 ADJUST PUMP LS CONTROL OIL PRESSURE...............................................312 TEST SOLENOID VALVE OUTLET PRESSURE...................................................313 TEST PPC VALVE OUTLET PRESSURE........................................................314 ADJUST WORK EQUIPMENT PPC VALVES PLAY.................................................316 TEST TRANSMISSION OIL PRESSURE........................................................317 TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT..........................319 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER ARM CYLINDER.........................319 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER BUCKET CYLINDER......................319 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BOOM CYLINDER.......................320 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE ARM CYLINDER........................320 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BUCKET CYLINDER.....................320 TEST PARTS CAUSING HYDRAULIC DRIFT OF BOOM SWING CYLINDER.........................320 BLEED AIR FROM HYDRAULIC SYSTEM.......................................................321 BLEED AIR FROM HYDRAULIC PUMP.....................................................321 BLEED AIR FROM CYLINDERS..........................................................321 WORK EQUIPMENT............................................................................323 OUTRIGGER SENSOR AND SAFETY SYSTEM....................................................323 CHECK AND ADJUST OUTRIGGER SENSOR.................................................323 TEST CORRECT FUNCTIONALITY OUTRIGGER SAFETY SYSTEM................................325 ADJUST RETURN TO DIG SENSOR...........................................................326 ADJUST TELESCOPIC ARM GUIDE SLACK.....................................................327 PREPARATION FOR ADJUSTING GUIDE SLACK.............................................327 REGISTRATION OF GUIDE SLACK.......................................................327 ELECTRICAL SYSTEM.........................................................................329 SET AND OPERATE MACHINE MONITOR.......................................................329 OPERATOR MODE.....................................................................331 FAST CHECK FAILURE CODE WHEN NO PROMPT ARE VISIBLE................................331 SET USAGE LIMITATION AND CHANGE PASSWORD..........................................331 SERVICE MODE......................................................................334 OPERATE SERVICE MODE..............................................................334 CHECK PRE-DEFINED MONITORING INFORMATION..........................................334 ABNORMALITY RECORD MENU...........................................................341 CHECK MAINTENANCE RECORD..........................................................342 MAINTENANCE MODE SETTING..........................................................344 SET PHONE NUMBER ENTRY............................................................348 DEFAULT SETTING MENU..............................................................350 START UP KOMTRAX TERMINAL.............................................................352 LAMP DISPLAY OF KOMTRAX TERMINAL......................................................356 ADJUST FRONT PANEL SETTINGS...........................................................359 PREPARATE KOMTRAX TERMINAL FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...................360 BATTERY DISCONNECT SWITCH.............................................................361 TEST DIODES...........................................................................362 TEST DIODES BY DIGITAL TESTER.....................................................362 TEST DIODES BY ANALOG TESTER......................................................362 40 TROUBLESHOOTING............................................................................363 CONTENTS..................................................................................364 RELATED INFORMATION TO TROUBLESHOOT.......................................................365 PRECAUTIONS FOR TROUBLESHOOTING.......................................................365 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................366 GENERAL TROUBLESHOOTING POINTS........................................................368 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM............................................369 CHECKS BEFORE TROUBLESHOOTING.........................................................370 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...........................................372 WALK-AROUND CHECK.................................................................372 TESTING IN ACCORDANCE WITH TESTING PROCEDURE..........................................374 CHECK FUEL LEVEL AND TYPE.........................................................374 CHECK WATER SEPARATOR AND DRAIN WATER AND SEDIMENT................................374 CHECK AdBlue(R) LEVEL AND TYPE....................................................376 REPLACE FUEL PREFILTER............................................................376 REPLACE FUEL MAIN FILTER..........................................................378 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE...........................379 CHECK COOLANT LEVEL (EXPANSION TANK)..............................................380 CHECK AIR CLEANER CLOGGING........................................................381 CLEAN OUTER ELEMENT...............................................................381 REPLACE INNER ELEMENT.............................................................383 CHECK HYDRAULIC OIL LEVEL.........................................................384 CHECK HYDRAULIC OIL STRAINER......................................................385 REPLACE HYDRAULIC OIL FILTER......................................................387 CHECK OIL LEVEL IN TRANSMISSION CASE..............................................388 CHECK FRONT AXLE OIL LEVEL........................................................389 CHECK REAR AXLE OIL LEVEL.........................................................389 BLEED AIR FROM SYSTEM.............................................................390 CHECK ELECTRIC EQUIPMENT..........................................................390 CONNECTOR CONTACT IDENTIFICATION......................................................395 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...............................................437 FUSE LOCATION TABLE...................................................................443 FAILURE CODE TABLE....................................................................447 ENGINE ECU FAILURE CODE TABLE.....................................................447 TRANSMISSION AND STEERING ECU FAILURE CODE TABLE..................................462 MACHINE ECU FAILURE CODE TABLE....................................................464 MONITOR ECU FAILURE CODE TABLE....................................................467 50 DISASSEMBLY AND ASSEMBLY...................................................................469 CONTENTS..................................................................................470 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...........................................474 HOW TO READ THIS MANUAL...............................................................474 COATING MATERIALS LIST................................................................476 ENGINE AND COOLING SYSTEM.................................................................480 REMOVE AND INSTALL RADIATOR ASSEMBLY..................................................480 REMOVE RADIATOR ASSEMBLY..........................................................480 INSTALL RADIATOR ASSEMBLY.........................................................483 REMOVE AND INSTALL OF FAN CLUTCH ASSEMBLY.............................................485 REMOVE FAN CLUTCH ASSEMBLY........................................................485 INSTALL FAN CLUTCH ASSEMBLY.......................................................488 REMOVE AND INSTALL ENGINE.............................................................489 REMOVE ENGINE.....................................................................489 INSTALL ENGINE ASSEMBLY...........................................................495 REMOVE AND INSTALL FUEL COOLER ASSEMBLY...............................................497 REMOVE FUEL COOLER ASSEMBLY.......................................................497 INSTALL FUEL COOLER ASSEMBLY......................................................497 REMOVE AND INSTALL EXHAUST PIPE.......................................................498 REMOVE EXHAUST PIPE...............................................................498 INSTALL EXHAUST PIPE..............................................................498 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY..............................................499 REMOVE BELLOWS PIPE ASSEMBLY......................................................499 INSTALL BELLOWS PIPE ASSEMBLY.....................................................500 REMOVE AND INSTALL TURBOCHARGER OUTLET NOx SENSOR.....................................502 REMOVE TURBOCHARGER OUTLET NOx SENSOR.............................................502 INSTALL TURBOCHARGER OUTLET NOx SENSOR............................................502 REMOVE AND INSTALL KDOC INLET TEMPERATURE SENSOR......................................504 REMOVE KDOC INLET TEMPERATURE SENSOR..............................................504 INSTALL KDOC INLET TEMPERATURE SENSOR.............................................504 REMOVE AND INSTALL SCR OUTLET NOx SENSOR..............................................506 REMOVE SCR OUTLET NOx SENSOR......................................................506 INSTALL SCR OUTLET NOx SENSOR.....................................................507 REMOVE AND INSTALL SCR OUTLET TEMPERATURE SENSOR......................................508 REMOVE SCR OUTLET TEMPERATURE SENSOR..............................................508 INSTALL SCR OUTLET TEMPERATURE SENSOR.............................................509 REMOVE AND INSTALL NH3 SENSOR.........................................................510 REMOVE NH3 SENSOR.................................................................510 INSTALL NH3 SENSOR................................................................511 REMOVE AND INSTALL KDOC ASSEMBLY......................................................512 REMOVE KDOC ASSEMBLY..............................................................512 INSTALL KDOC ASSEMBLY.............................................................515 REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY....................................517 REMOVE DEF TANK SENSOR FLANGE ASSEMBLY............................................517 INSTALL DEF TANK SENSOR FLANGE ASSEMBLY...........................................521 REMOVE AND INSTALL DEF TANK SENSOR....................................................522 REMOVE DEF TANK SENSOR............................................................522 INSTALL DEF TANK SENSOR...........................................................522 REMOVE AND INSTALL DEF TANK STRAINER..................................................524 REMOVE DEF TANK STRAINER..........................................................524 INSTALL DEF TANK STRAINER.........................................................524 REMOVE AND INSTALL DEF INJECTOR.......................................................525 REMOVE DEF INJECTOR...............................................................525 INSTALL DEF INJECTOR..............................................................527 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...............................................531 REMOVE AIR CLEANER ASSEMBLY.......................................................531 INSTALL AIR CLEANER ASSEMBLY......................................................531 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.................................532 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY.........................................532 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY........................................533 REMOVE AND INSTALL AIR CONDITIONER BELT...............................................534 REMOVE AIR CONDITIONER BELT.......................................................534 INSTALL AIR CONDITIONER BELT......................................................534 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR.........................................535 REMOVE AIR CONDITIONER COMPRESSOR.................................................535 INSTALL AIR CONDITIONER COMPRESSOR................................................537 UNDERCARRIAGE AND FRAME...................................................................538 REMOVE AND INSTALL ENGINE HOOD........................................................538 REMOVE ENGINE HOOD................................................................538 INSTALL ENGINE HOOD...............................................................539 REMOVE AND INSTALL COUNTERWEIGHT......................................................540 REMOVE COUNTERWEIGHT..............................................................540 INSTALL COUNTERWEIGHT.............................................................540 REMOVE AND INSTALL FRONT AND REAR WHEELS..............................................542 REMOVE FRONT WHEELS...............................................................542 INSTALL FRONT WHEELS..............................................................542 REMOVE REAR WHEELS................................................................542 INSTALL REAR WHEELS...............................................................543 POWER TRAIN...............................................................................544 REMOVE AND INSTALL FRONT AXLE.........................................................544 REMOVE FRONT AXLE.................................................................544 INSTALL FRONT AXLE................................................................545 DISASSEMBLE AND ASSEMBLE FRONT AXLE...................................................546 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER GROUP..................................546 DISASSEMBLE AND ASSEMBLE EPICYCLIC REDUCTION GEAR GROUP...........................549 DISASSEMBLE AND ASSEMBLE WHEEL HUB GROUP..........................................552 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................558 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL GROUP.......................................567 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................569 DISASSEMBLE AND ASSEMBLE AXLE BEAM GROUP..........................................576 DISASSEMBLE AND ASSEMBLE WHEEL AND DOUBLE U-JOINT GROUP...........................579 TESTING AFTER ASSEMBLY............................................................583 REMOVE AND INSTALL REAR AXLE..........................................................584 REMOVE REAR AXLE..................................................................584 INSTALL REAR AXLE.................................................................585 DISASSEMBLE AND ASSEMBLE REAR AXLE....................................................586 DISASSEMBLE AND ASSEMBLE BRAKE GROUP..............................................586 DISASSEMBLE AND ASSEMBLE WHEEL HUB AND REDUCTION GEAR.............................595 DISASSEMBLE AND ASSEMBLE PARKING BRAKE............................................604 DISASSEMBLE AND ASSEMBLE PARKING BRAKE MECHANICAL CALIPER.........................607 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................609 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL LOCKING GROUP...............................617 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL.............................................621 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................628 TESTING AFTER ASSEMBLY............................................................635 REMOVE AND INSTALL TRANSMISSION.......................................................636 REMOVE TRANSMISSION...............................................................636 INSTALL TRANSMISSION..............................................................641 DISASSEMBLE AND ASSEMBLE TRANSMISSION.................................................642 DISASSEMBLE AND ASSEMBLE PLUGS, FILTERS AND SENSORS...............................642 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER AND OIL PUMP............................648 DISASSEMBLE AND ASSEMBLE HYDRAULIC CONTROL VALVE..................................652 DISASSEMBLE AND ASSEMBLE HYDRAULIC SYSTEM PIPES...................................657 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER VALVOLE KIT.............................661 DISASSEMBLE AND ASSEMBLE TRANSMISSION HOUSING.....................................663 DISASSEMBLE AND ASSEMBLE SHAFTS A - D.............................................672 DISASSEMBLE AND ASSEMBLE SHAFT B..................................................689 DISASSEMBLE AND ASSEMBLE SHAFT C..................................................702 DISASSEMBLE AND ASSEMBLE SHAFT E..................................................729 HYDRAULIC SYSTEM..........................................................................742 REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY............................................742 REMOVE HYDRAULIC PUMP ASSEMBLY....................................................742 INSTALL HYDRAULIC PUMP ASSEMBLY...................................................744 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.........................746 DISASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................746 ASSEMBLY WORK EQUIPMENT PPC VALVE.................................................746 WORK EQUIPMENT............................................................................748 REMOVE AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY.....................................748 REMOVE LOADER WORK EQUIPMENT ASSEMBLY.............................................748 INSTALL LOADER WORK EQUIPMENT ASSEMBLY............................................750 REMOVE AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY....................................752 REMOVE BACKHOE WORK EQUIPMENT ASSEMBLY............................................752 INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY...........................................754 REMOVE AND INSTALL BACKHOE BOOM CYLINDER..............................................755 REMOVE BACKHOE BOOM CYLINDER......................................................755 INSTALL BACKHOE BOOM CYLINDER.....................................................757 REMOVE AND INSTALL BACKHOE ARM CYLINDER...............................................758 REMOVE BACKHOE ARM CYLINDER.......................................................758 INSTALL BACKHOE ARM CYLINDER......................................................759 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER....................................760 REMOVE BACKHOE TELESCOPIC ARM CYLINDER............................................760 INSTALL BACKHOE TELESCOPIC ARM CYLINDER...........................................760 REMOVE AND INSTALL OUTRIGGER CYLINDER.................................................761 REMOVE OUTRIGGER CYLINDER.........................................................761 INSTALL OUTRIGGER CYLINDER........................................................762 REMOVE AND INSTALL BACKHOE BOOM SWING CYLINDERS.......................................763 REMOVE BACKHOE BOOM SWING CYLINDERS...............................................763 INSTALL BACKHOE BOOM SWING CYLINDERS..............................................764 REMOVE AND INSTALL BACKHOE BUCKET CYLINDER............................................765 REMOVE BACKHOE BUCKET CYLINDER....................................................765 INSTALL BACKHOE BUCKET CYLINDER...................................................765 REMOVE AND INSTALL BACKHOE BOOM LOCK CYLINDER.........................................767 REMOVE BACKHOE BOOM LOCK CYLINDER.................................................767 INSTALL BACKHOE BOOM LOCK CYLINDER................................................767 REMOVE AND INSTALL BACKHOE BOOM.......................................................768 REMOVE BACKHOE BOOM...............................................................768 INSTALL BACKHOE BOOM..............................................................768 REMOVE AND INSTALL BACKHOE ARM ASSEMBLY...............................................770 REMOVE BACKHOE ARM ASSEMBLY.......................................................770 INSTALL BACKHOE ARM...............................................................770 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY....................................772 REMOVE BACKHOE TELESCOPIC ARM ASSEMBLY............................................772 INSTALL BACKHOE TELESCOPIC ARM....................................................772 REMOVE AND INSTALL BACKHOE BOOM SWING BRACKET.........................................774 REMOVE BACKHOE BOOM SWING BRACKET.................................................774 INSTALL BACKHOE BOOM SWING BRACKET................................................774 REMOVE AND INSTALL BACKHOE SLIDING BRACKET............................................776 REMOVE BACKHOE SLIDING BRACKET....................................................776 INSTALL BACKHOE SLIDING BRACKET...................................................777 REMOVE AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON.............................778 REMOVE BACKHOE SLIDING BRACKET LOCKING PISTON.....................................778 INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON....................................778 CAB AND ITS ATTACHMENTS...................................................................780 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY............................................780 REMOVE OPERATOR'S CAB ASSEMBLY....................................................780 INSTALL OPERATOR'S CAB ASSEMBLY...................................................788 ELECTRICAL SYSTEM.........................................................................790 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY.........................................790 REMOVE ENGINE CONTROLLER ASSEMBLY.................................................790 INSTALL ENGINE CONTROLLER ASSEMBLY................................................792 REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...................................793 REMOVE TRANSMISSION CONTROLLER ASSEMBLY...........................................793 INSTALL TRANSMISSION CONTROLLER ASSEMBLY..........................................795 REMOVE AND INSTALL FRONT PANEL........................................................796 REMOVE FRONT PANEL................................................................796 INSTALL FRONT PANEL...............................................................797 REMOVE AND INSTALL STEERING COLUMN SWITCHES...........................................798 REMOVE STEERING COLUMN SWITCHES...................................................798 INSTALL STEERING COLUMN SWITCHES..................................................799 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY..........................................800 REMOVE KOMTRAX TERMINAL ASSEMBLY..................................................800 INSTALL KOMTRAX TERMINAL ASSEMBLY.................................................800 REMOVE AND INSTALL BACKHOE PPC VALVE..................................................802 REMOVE BACKHOE PPC VALVE..........................................................802 INSTALL BACKHOE PPC VALVE.........................................................803 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES...........................804 REMOVE BACKHOE PPC VALVE SUPPORT RELEASE CABLES...................................804 INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES..................................805 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING........................806 REMOVE BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING................................806 INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRINGS..............................807 60 MAINTENANCE STANDARD.......................................................................809 CONTENTS..................................................................................810 ENGINE AND COOLING SYSTEM.................................................................811 MAINTENANCE STANDARD OF ENGINE MOUNT..................................................811 MAINTENANCE STANDARD OF COOLING SYSTEM................................................813 POWER TRAIN...............................................................................814 MAINTENANCE STANDARD OF TRANSMISSION..................................................814 MAINTENANCE STANDARD OF FRONT AXLE....................................................817 MAINTENANCE STANDARD OF REAR AXLE.....................................................822 HYDRAULIC SYSTEM..........................................................................827 MAINTENANCE STANDARD OF MAIN PUMP.....................................................827 MAINTENANCE STANDARD OF CONTROL VALVE.................................................829 WORK EQUIPMENT............................................................................839 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT PPC VALVE...............................839 LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................................839 LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.................842 MAINTENANCE STANDARD OF SWING BRACKET.................................................845 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT.........................................847 MAINTENANCE STANDARD OF BACKHOE WORK EQUIPMENT........................................849 MAINTENANCE STANDARD OF WORK EQUIPMENT CYLINDERS......................................851 LOADER ARM CYLINDER...............................................................851 LOADER BUCKET CYLINDER............................................................851 LOADER BUCKET 4 IN 1 CYLINDER.....................................................852 BACKHOE BOOM CYLINDER.............................................................853 BACKHOE ARM CYLINDER..............................................................853 BACKHOE BUCKET CYLINDER...........................................................854 BACKHOE BOOM SWING CYLINDER.......................................................855 BACKHOE TELESCOPIC ARM CYLINDER...................................................856 OUTRIGGER CYLINDER................................................................856 90 CIRCUIT DIAGRAMS...........................................................................859 CONTENTS..................................................................................860 HOW TO READ THE CODES FOR ELECTRIC CABLE..................................................861 HYDRAULIC CIRCUIT DIAGRAM.................................................................865 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.............................................865 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (1/2)....................................869 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (2/2)....................................871 ELECTRICAL CIRCUIT DIAGRAM................................................................873 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM..............................................873 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/12)..........................................877 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/12)..........................................879 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/12)..........................................881 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/12)..........................................883 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/12)..........................................885 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/12)..........................................887 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/12)..........................................889 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/12)..........................................891 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/12)..........................................893 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/12).........................................895 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/12).........................................897 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (12/12).........................................899
DESCRIPTION:
KOMATSU XWB97R-8 BACKHOE LOADER SHOP MANUAL WENBM00260 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
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