Komatsu WA100 Wheel Loader Repair Service Manual & Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu WA100 Wheel Loader, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu WA100 Wheel Loader workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEAM04160101 - Wheel Loader WA100-1, WA150-1 Operation & Maintenance Manual.pdf
SEBM04160105 - Wheel Loader WA100-1 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 740 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
SEAM04160101 - Wheel Loader WA100-1, WA150-1 Operation & Maintenance Manual...1
COVER...1
FOREWORD...2
BREAKING IN YOUR NEW MACHINE...3
CONTENTS...4
SAFETY HINTS...5
GENERAL LOCATIONS AND SPECIFICATIONS...12
INSTRUMENTS AND CONTROLS...13
CHECK BEFORE STARTING...35
OPERATING YOUR MACHINE...39
ADJUSTMENT OF WORK EQUIPMENT...47
HANDLING THE TIRES...49
TOWING...52
TRANSPORTATION...53
HANDLING OF BATTERY...54
COLD WEATHER OPERATION...57
PERIODIC MAINTENANCE...61
PRECAUTIONS FOR MAINTENANCE...62
MAINTENANCE TABLE...66
OIL FILLER AND LEVEL GAUGE POSITIONS...69
EVERY 50 HOURS SERVICE...70
EVERY 100 HOURS SERVICE...71
INITIAL 250 HOURS SERVICE...73
EVERY 250 HOURS SERVICE...73
EVERY 500 HOURS SERVICE...79
EVERY 1000 HOURS SERVICE...83
EVERY 2000 HOURS SERVICE...88
EVERY 4000 HOURS SERVICE...91
WHEN REQUIRED...92
ADJUSTMENT...103
TROUBLE SHOOTING GUIDE...105
STORAGE...108
SERVICE METER...110
MACHINE AND ENGINE SERIAL NUMBERS...111
FUEL,COOLANT AND LUBRICANTS...112
SEBM04160105 - Wheel Loader WA100-1 Shop Manual...115
COVER...115
CONTENTS...116
10 ENGINE...153
11 STRUCTURE AND FUNCTION...153
ENGINE MOUNT...154
RADIATOR AND COOLER...155
FUEL TANK AND PIPING...157
ENGINE CONTROL...158
12 TESTING AND ADJUSTING...159
STANDARD VALUE TABLE...160
TOOL LIST FOR TESTING AND ADJUSTING...161
ADJUSTING VALVE CLEARANCE...162
MEASURING COMPRESSION PRESSURE...163
TESTING AND ADJUSTING FUEL INJECTION TIMING...164
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE...165
MEASURING BLOW-BY PRESSURE...166
TESTING AND ADJUSTING FAN BELT TENSION...167
MEASURING EXHAUST GAS COLOR...168
MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL...169
13 DISASSEMBLY AND ASSEMBLY...173
STARTING MOTOR...174
REMOVAL...174
INSTALLATION...174
ALTERNATOR...175
REMOVAL...175
INSTALLATION...175
FUEL INJECTION PUMP...176
REMOVAL...176
INSTALLATION...177
WATER PUMP...179
REMOVAL...179
INSTALLATION...180
NOZZLE HOLDER...181
REMOVAL (SERIAL NO.10001-19999)...181
INSTALLATION (SERIAL NO.10001-19999)...181
REMOVAL (SERIAL NO.20001-)...182
INSTALLATION (SERIAL NO.20001-)...182
CYLINDER HEAD...184
REMOVAL...184
INSTALLATION...190
RADIATOR...196
REMOVAL...196
INSTALLATION...199
ENGINE...202
REMOVAL...202
INSTALLATION...208
FUEL TANK...214
REMOVAL...214
INSTALLATION...215
20 POWER TRAIN...217
21 STRUCTURE AND FUNCTION...217
GENERAL...218
HYDRAULIC CIRCUIT FOR POWER TRAIN...220
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...221
FORWARD 1ST...222
TORQUE CONVERTER AND TRANSMISSION PIPING...224
TORQUE CONVERTER CHARGING PUMP...225
TORQUE CONVERTER...226
TORQUE CONVERTER OIL FILTER...228
TORQFLOW TRANSMISSION...230
CLUTCH PACK...233
TRANSMISSION CONTROL VALVE...242
MAIN REGULATOR VALVE...244
TORQUE CONVERTER OIL OUTLET VALVE...245
QUICK RETURN VALVE AND ACCUMULATOR...246
POWER MODULATING FUNCTION...248
ACCUMULATOR VALVE...252
ACTION OF THE CLUTCH CUT-OFF VALVE...253
DRIVE SHAFT...255
AXLE...256
DIFFERENTIAL...258
FINAL DRIVE...262
AXLE MOUNT...264
TIRE AND WHEEL...266
22 TESTING AND ADJUSTING...267
STANDARD VALUE TABLE...268
TOOL LIST FOR TESTING AND ADJUSTING...269
MEASURING ENGINE STALL SPEED...270
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION...272
MEASURING SHIFT LEVER...274
MEASURING VALVE SPOOL OPERATING FORCE AND TRAVEL...275
TROUBLESHOOTING...277
PRECAUTIONS WHEN TROUBLESHOOTING...278
METHOD OF READING TROUBLESHOOTING TABLE...280
PREVENTING RECURRENCE OF TROUBLE...282
TROUBLESHOOTING TABLE...284
1. MACHINE DOES NOT MOVE OFF...284
2. MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF...286
3. LARGE SHOCK WHEN MOVING OFF OR CHANGING GEAR...288
4. LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR...289
5. OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH...290
23 DISASSEMBLY AND ASSEMBLY...291
TORQUE CONVERTER CHARGING PUMP...292
REMOVAL...292
INSTALLATION...292
TORQUE CONVERTER, TRANSMISSION...294
REMOVAL...294
INSTALLATION...304
TORQUE CONVERTER...312
DISASSEMBLY...312
ASSEMBLY...315
TRANSMISSION...318
DISASSEMBLY...318
ASSEMBLY...328
CLUTCH PACK...342
DISASSEMBLY...342
ASSEMBLY...350
TRANSMISSION VALVE...364
REMOVAL...364
INSTALLATION...366
TRANSMISSION CONTROL VALVE...368
DISASSEMBLY...368
ASSEMBLY...372
DRIVE SHAFT...378
DISASSEMBLY...378
ASSEMBLY...380
FRONT AXLE...382
REMOVAL...382
INSTALLATION...384
REAR AXLE...386
REMOVAL...386
INSTALLATION...390
DIFFERENTIAL...396
DISASSEMBLY...396
ASSEMBLY...400
AXLE HOUSING...410
DISASSEMBLY...410
ASSEMBLY...415
24 MAINTENANCE STANDARD...423
TRANSMISSION AND ENGINE MOUNT...424
TORQUE CONVERTER CHARGING PUMP...425
TORQUE CONVERTER...426
TRANSMISSION...428
TRANSMISSION CLUTCH ASSEMBLY...430
TRANSMISSION CONTROL VALVE...432
AXLE...434
DIFFERENTIAL...436
FINAL DRIVE...438
DRIVE SHAFT...439
AXLE MOUNT...440
40 STEERING SYSTEM...443
41 STRUCTURE AND FUNCTION...443
GENERAL...444
HYDRAULIC CIRCUIT FOR STEERING...446
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...447
OPERATIONS OF STEERING VALVE...448
STEERING VALVE (SERIAL NO. 10001-19999)...450
STEERING RELIEF VALVE...452
SAFETY VALVE (WITH SUCTION VALVE)...453
OPERATION OF DEMAND VALVE...455
TWO-WAY RESTRICTOR VALVE...456
STEERING VALVE (SERIAL NO. 20001-)...458
PRIORITY VALVE...466
STEERING COLUMN AND GEAR BOX...469
STEERING LINKAGE...470
STEERING CYLINDER...471
CENTER HINGE PIN...472
42 TESTING AND ADJUSTING...473
STANDARD VALUE TABLE...474
TOOL LIST FOR TESTING AND ADJUSTING...474
MEASURING STEERING WHEEL PLAY...475
MEASURING OPERATING FORCE OF STEERING WHEEL...476
OPERATING TIME OF STEERING WHEEL...477
TESTING STEERING LINKAGE...478
ADJUSTING STEERING LINKAGE...479
STEERING OIL PRESSURE...480
TROUBLESHOOTING...481
TROUBLESHOOTING TABLE...482
1. STEERING WHEEL DOES NOT TURN...482
2. STEERING WHEEL IS SLUGGISH...484
3. STEERING WHEEL MOVE UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK...486
4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING...486
5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT...486
43 DISASSEMBLY AND ASSEMBLY...489
STEERING GEAR BOX...490
REMOVAL...490
INSTALLATION...491
DISASSEMBLY...492
ASSEMBLY...493
STEERING VALVE...496
REMOVAL...496
INSTALLATION...497
DISASSEMBLY...498
ASSEMBLY...500
PRIORITY VALVE...502
REMOVAL...502
INSTALLATION...503
STEERING VALVE...504
REMOVAL...504
INSTALLATION...505
STEERING CYLINDER...506
REMOVAL...506
INSTALLATION...506
DISASSEMBLY...508
ASSEMBLY...510
CENTER HINGE PIN...514
REMOVAL...514
INSTALLATION...524
44 MAINTENCE STANDARD...535
STEERING VALVE...536
STEERING CYLINDER MOUNT...538
STEERING CYLINDER...539
CENTER HINGE PIN...540
STEERING LINKAGE...542
STEERING COLUMN AND GEAR BOX...543
STEERING COLUMN...544
PRIORITY VALVE...545
50 BRAKE SYSTEM...547
51 STRUCTURE AND FUNCTION...547
GENERAL...548
BRAKE MASTER CYLINDER...550
BRAKE...552
PARKING BRAKE...554
BRAKE CALIPER...556
52 TESTING AND ADJUSTING...557
STANDARD VALUE TABLE...558
TOOL LIST FOR TESTING AND ADJUSTING...559
MEASURING BRAKE PEDAL...560
TESTING AND ADJUSTING OF BRAKE PEDAL LINKAGE...561
BRAKE PERFORMANCE...563
CHECKING BRAKE PISTON LEAKAGE...564
MEASURING WEAR OF BRAKE DISC...565
AIR BLEEDING FROM BRAKE LINE...566
PARKING BRAKE PERFORMANCE...567
CHECKING AND ADJUSTING PARKING BRAKE...568
MEASURING CLEARANCE...570
TROUBLESHOOTING...571
TROUBLESHOOTING TABLE...572
1. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE...572
2. BRAKE CANNOT BE RELEASED OR DRAGS...573
53 DISASSEMBLY AND ASSEMBLY...575
MASTER CYLINDER...576
REMOVAL...576
INSTALLATION...577
DISASSEMBLY...578
ASSEMBLY...579
PARKING BRAKE...580
REMOVAL...580
INSTALLATION...582
PARKING BRAKE PAD...584
REMOVAL...584
INSTALLATION...585
54 MAINTENANCE STANDARD...587
BRAKE MASTER CYLINDER...588
BRAKE...589
PARKING BRAKE...590
60 WORK EQUIPMENT SYSTEM...591
61 STRUCTURE AND FUNCTION...591
GENERAL...592
HYDRAULIC CIRCUIT (SERIAL NO.10001-19999)...594
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.10001-19999)...595
HYDRAULIC CIRCUIT (SERIAL NO.20001-)...596
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.20001-)...597
DUMP AND LIFT CONTROL LEVER LINKAGE...598
BUCKET LINKAGE...600
BUCKET POSITIONER AND BOOM KICK-OUT...602
HYDRAULIC TANK...603
OIL FILTER BYPASS VALVE...606
BREATHER...606
HYDRAULIC AND STEERING PUMP...607
MAIN CONTROL VALVE...608
RELIEF VALVE...610
SAFETY VALVE...611
SUCTION VALVE...612
HYDRAULIC CYLINDER...619
62 TESTING AND ADJUSTING...621
STANDARD VALUE TABLE...622
TOOL LIST FOR TESTING AND ADJUSTING...623
MEASURING DUMP AND LIFT CONTROL LEVERS...624
ADJUSTING DUMP AND LIFT CONTROL LEVERS...625
MEASURING DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL...626
MEASURING HYDRAULIC PRESSURE...627
MEASURING LIFT ARM AND BUCKET...629
MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET...630
ADJUSTING BUCKET POSITIONER...631
ADJUSTING BOOM KICK-OUT...632
TROUBLESHOOTING...633
TROUBLESHOOTING TABLE...634
1. LIFT ARM DOES NOT RISE...634
2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...635
3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT...636
4. BUCKET CANNOT BE HOLD DOWN WITH LIFT ARM CYLINDER...636
5. LIFT ARM HAS LARGE HYDRAULIC DRIFT...636
6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK...636
7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"...636
8. BUCKET DOES NOT TILT BACK...637
9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...638
10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK...639
11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER...639
12. BUCKET HAS LARGE HYDRAULIC DRIFT...639
13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD...639
14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"...639
15. CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY...640
63 DISASSEMBLY AND ASSEMBLY...641
HYDRAULIC TANK...642
REMOVAL...642
INSTALLATION...643
HYDRAULIC FILTER...644
REMOVAL...644
INSTALLATION...644
HYDRAULIC-STEERING PUMP...645
REMOVAL...645
INSTALLATION...645
MAIN CONTROL VALVE...646
REMOVAL...646
INSTALLATION...648
DISASSEMBLY...650
ASSEMBLY...652
DUMP CYLINDER...654
REMOVAL...654
INSTALLATION...656
LIFT CYLINDER...658
REMOVAL...658
INSTALLATION...659
LIFT AND DUMP CYLINDER...660
DISASSEMBLY...660
ASSEMBLY...662
WORK EQUIPMENT...666
REMOVAL...666
INSTALLATION...669
COUNTERWEIGHT...672
REMOVAL...672
INSTALLATION...672
64 MAINTENANCE STANDARD...673
MAIN CONTROL VALVE...674
DUMP CYLINDER...676
LIFT CYLINDER...677
WORK EQUIPMENT...678
BUCKET POSITIONER AND BOOM KICK-OUT...680
BUCKET...681
HYDRAULIC AND STEERING PUMP...682
80 ELECTRIC AND ELECTRONIC SYSTEM...683
81 STRUCTURE AND FUNCTION...683
CLUSTER GAUGE...684
PROXIMITY SWITCH...686
ENGINE STARTING CIRCUIT...688
ENGINE STOP CIRCUIT...689
PREHEATING CIRCUIT...690
PREHEATING WITH STARTING SWITCH...690
ELECTRICAL WIRING DIAGRAM...691
ELECTRICAL WIRING DIAGRAM CIRCUIT...692
SENSOR...694
83 DISASSEMBLY AND ASSEMBLY...699
INSTRUMENT PANEL...700
REMOVAL...700
INSTALLATION...701
90 OTHERS...703
91 STRUCTURE AND FUNCTION...703
CAB...704
AIR CONDITIONER (OPTION)...705
AIR CONDITIONER PIPING...705
AIR CONDITIONER WIRING DIAGRAM...706
AIR CONDITIONER ELECTRIC CIRCUIT...706
AIR CONDITIONER UNIT...707
AIR CONDITIONER COMPRESSOR...708
AIR CONDITIONER CONDENSOR...708
AIR CONDITIONER DRY RESERVOIR...709
93 DISASSEMBLY AND ASSEMBLY...711
CAB...712
REMOVAL...712
INSTALLATION...713
97 GEAR PUMP...715
GENERAL...715
GENERAL...716
PRINCIPLE OF OPERATION...717
PRESSURE LOADED TYPE GEAR PUMP...720
FIXED SIDE PLATE TYPE GEAR PUMP...722
SA SERIES...723
STRUCTURE...724
TESTING AND ADJUSTING...727
DISASSEMBLY...730
ASSEMBLY...734
MAINTENANCE STANDARD...739
Komatsu WA100 Wheel Loader Repair Service Manual & Operation Maintenance Manual
