Komatsu Backhoe Loader WB97R-8E0 service & repair manual

Description Komatsu Backhoe Loader WB97R-8E0 service & repair manual

Komatsu Backhoe Loader WB97R-8E0 pdf workshop service repair manual

Serial numbers:
F65001 and up

Technical data, specifications, testing, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly instructions and other information

MANUAL CONTENT:
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR DEF
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
ABBREVIATION LIST

SPECIFICATIONS
SPECIFICATION DRAWING
WEIGHT TABLE
FUEL, COOLANT, LUBRICANTS

STRUCTURE AND FUNCTION
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
CLSS
COMPONENT PARTS OF HYDRAULIC SYSTEM
POWER TRAIN SYSTEM
LAYOUT DRAWING OF POWER TRAIN SYSTEM
OPERATION OF POWER TRAIN SYSTEM
COMPONENT PARTS OF POWER TRAIN SYSTEM
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
LOADER WORK EQUIPMENT PPC VALVE
BACKHOE PPC VALVE
OUTRIGGER PPC VALVE
STEERING UNIT
BRAKE PUMP
SOLENOID VALVES
PPC CIRCUIT ACCUMULATOR
SAFETY VALVES
WORK EQUIPMENT
STRUCTURE OF LOADER WORK EQUIPMENT
STRUCTURE OF BACKHOE WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR MACHINE
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE

TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST VISUAL CHECK CRANKCASE SYSTEM
TEST CHECK CYLINDER MECHANICS
TEST CHECK EGR VALVE ACTUATOR
TEST CHECK EXTERNAL FUEL LEAKAGE ENGINE AREA
TEST CHECK PRESSURE LIMITING VALVE (PLV) BACKFLOW RATE
TEST CHECK TURBO SYSTEM
TEST CHECK INTAKE AIR SYSTEM
TEST CHECK COOLING SYSTEM
CHECK PRESSURE BETWEEN MAIN FILTER AND HIGH PRESSURE PUMP
TEST CHECK HIGH PRESSURE PUMP BACKFLOW RATE
TEST CHECK HIGH PRESSURE SYSTEM BACKFLOW RATE
PRESSURE TEST RAIL PRESSURE ADJUSTMENT CHECK
PRESSURE TEST CHECK RAIL PRESSURE DURING RAIL
PRESSURE TEST CHECK PRESSURE BETWEEN GEAR PUMP AND MAIN FILTER
TEST CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR
PRESSURE TEST CHECK SUCTION PRESSURE BETWEEN TANK AND PRE-FILTER
PRESSURE TEST CHECK SUCTION PRESSURE AFTER PRE-FILTER
TEST CHECK WATER IN FUEL SENSOR PLAUSIBILITY
TEST CHECK EXTERNAL FUEL LEAKAGE HIGH PRESSURE SYSTEM
TEST CHECK SINGLE INJECTOR BACKFLOW RATE
TEST INJECTOR CUT OUT ACTIVATION CHECK
TEST ENGINE SPEED
TEST EXHAUST GAS COLOR
STEERING SYSTEM
CHECK LEAKAGES IN STEERING CYLINDER
TEST STEERING CIRCUIT OIL PRESSURE
ADJUST TOE-IN/STEERING ANGLE WITH AXLES REMOVED FROM MACHINE
ADJUST TOE-IN/STEERING ANGLE WITH AXLES WITHOUT REMOVED FROM MACHINE
BRAKE SYSTEM
TEST BRAKE SYSTEM PRESSURE
TEST BRAKE SYSTEM LEAKAGE
TEST BRAKE PISTON STROKE
BLEED AIR FROM THE BRAKE CIRCUIT
ADJUST BRAKE PEDAL TRAVEL
TEST AND ADJUST PARKING BRAKE SYSTEM
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT
TEST AND ADJUST HYDRAULIC CIRCUIT PRESSURE
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE
TEST AND ADJUST CONTROL CIRCUIT OIL PRESSURE
MEASURE AND ADJUST PUMP PC CONTROL OIL PRESSURE
MEASURE AND ADJUST PUMP LS CONTROL OIL PRESSURE
TEST SOLENOID VALVE OUTLET PRESSURE
TEST PPC VALVE OUTLET PRESSURE
ADJUST WORK EQUIPMENT PPC VALVES PLAY
TEST TRANSMISSION OIL PRESSURE
TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
BLEED AIR FROM HYDRAULIC SYSTEM
WORK EQUIPMENT
OUTRIGGER SENSOR AND SAFETY SYSTEM
ADJUST RETURN TO DIG SENSOR
ADJUST TELESCOPIC ARM GUIDE SLACK
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
START UP KOMTRAX TERMINAL
LAMP DISPLAY OF KOMTRAX TERMINAL
ADJUST FRONT PANEL SETTINGS
PREPARATE KOMTRAX TERMINAL FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
BATTERY DISCONNECT SWITCH
TEST DIODES

TROUBLESHOOTING
RELATED INFORMATION TO TROUBLESHOOT
PRECAUTIONS FOR TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
FAILURE CODE TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)

DISASSEMBLY AND ASSEMBLY
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL OF FAN CLUTCH ASSEMBLY
REMOVE AND INSTALL ENGINE
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVE AND INSTALL EXHAUST PIPE
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY
REMOVE AND INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC
REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC
REMOVE AND INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR
REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR
REMOVE AND INSTALL DOC ASSEMBLY
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY
REMOVE AND INSTALL DEF TANK SENSOR
REMOVE AND INSTALL DEF TANK STRAINER
REMOVE AND INSTALL DEF INJECTOR
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER BELT
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR
UNDERCARRIAGE AND FRAME
REMOVE AND INSTALL ENGINE HOOD
REMOVE AND INSTALL COUNTERWEIGHT
REMOVE AND INSTALL FRONT AND REAR WHEELS
POWER TRAIN
REMOVE AND INSTALL FRONT AXLE
DISASSEMBLE AND ASSEMBLE FRONT AXLE
REMOVE AND INSTALL REAR AXLE
DISASSEMBLE AND ASSEMBLE REAR AXLE
REMOVE AND INSTALL TRANSMISSION
DISASSEMBLE AND ASSEMBLE TRANSMISSION
HYDRAULIC SYSTEM
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY
REMOVE AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY
REMOVE AND INSTALL BACKHOE BOOM CYLINDER
REMOVE AND INSTALL BACKHOE ARM CYLINDER
REMOVE AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER
REMOVE AND INSTALL OUTRIGGER CYLINDER
REMOVE AND INSTALL BACKHOE BOOM SWING CYLINDERS
REMOVE AND INSTALL BACKHOE BUCKET CYLINDER
REMOVE AND INSTALL BACKHOE BOOM LOCK CYLINDER
REMOVE AND INSTALL BACKHOE BOOM
REMOVE AND INSTALL BACKHOE ARM ASSEMBLY
REMOVE AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY
REMOVE AND INSTALL BACKHOE BOOM SWING BRACKET
REMOVE AND INSTALL BACKHOE SLIDING BRACKET
REMOVE AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY
REMOVE AND INSTALL FRONT PANEL
REMOVE AND INSTALL STEERING COLUMN SWITCHES
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
REMOVE AND INSTALL BACKHOE PPC VALVE
REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES
REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING

MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF COOLING SYSTEM
POWER TRAIN
MAINTENANCE STANDARD OF TRANSMISSION
MAINTENANCE STANDARD OF FRONT AXLE
MAINTENANCE STANDARD OF REAR AXLE
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF MAIN PUMP
MAINTENANCE STANDARD OF CONTROL VALVE
WORK EQUIPMENT
MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT PPC VALVE
MAINTENANCE STANDARD OF SWING BRACKET
MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT
MAINTENANCE STANDARD OF BACKHOE WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT CYLINDERS

CIRCUIT DIAGRAMS
HOW TO READ THE CODES FOR ELECTRIC CABLE
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM

Engine SAA4D102SE-1 workshop service manual