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  9. Komatsu avance WB97R-2 Install guide

Komatsu avance WB97R-2 Install guide

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WEBM001000
Shop
Manual
-2
BACKHOE LOADER
SERIAL NUMBERS WB97R-2 97F20001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu
Printed in U.S.A.
Komatsu America Corp.
July 2007
00-2
WB97R-2
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CONTENTS
WB97R-2
No. of page
10 STRUCTURE AND FUNCTION ............................................. 10-1
20 TESTING AND ADJUSTING ................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY........................................... 30-1
40 MAINTENANCE STANDARD ............................................... 40-1
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00-2
WB97R-2
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Pages having no marks are those previousl revised
or made additions.
00-2-1
WB97R-2
Mark Indication Action required
CPage to be newl Add
cPage to be replaced Replace
( ) Page to be delete Discard
LIST OF REVISED PAGES
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00-2-2
WB97R-2
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GENERAL PRECAUTIONS
Mistakes in operation extremel dangerous.
Read all the Operation and Maintenance Manual care-
full BEFORE operating the machine.
1. Before carr ing out an greasing or repairs, read
all the precautions written on the decals which
are suck on the machine.
2. When carr ing out an operation, alwa s wear
safet shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
.Alwa s wear safet glasses when hitting parts
with a hammer.
.Alwa s wear safet glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, alwa s have a
trained, experienced welder carr out the work.
When carr ing out welding work, alwa s wear
welding gloves, apron, glasses, cap and other
clothes suited for welding work.
4. When carr ing out an operation with two or more
workers, alwa s agree on the operating procedure
before starting. Alwa s inform our fellow workers
before starting an step of the operation. Before
starting work, hang UNDER REPAIR signs on
the controls in the operator's compartment.
5. Keep all tools in good condition and learn the cor-
rect wa to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Alwa s keep the tools
and parts in their correct places. Alwa s keep
the work area clean and make sure that there is
no dirt or oil on the floor.
Smoke onl in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding or making an repairs, park the ma-
chine on hard, level ground, and block the wheels
to prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or
an other work equipment to the ground. If this
is not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
to lock all the control levers and hang warning
sign on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before start-
ing work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Alwa s
use the handrails, ladders or steps when getting
on or off the machine.
Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or h -
draulic pressure measuring plugs, loosen them
slowl to prevent the oil from spurting out.
Before disconnecting or removing components of
the h draulic circuit and engine cooling circuit,
first remove the pressure completel from the cir-
cuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carr ing out
an work on the cooling water circuits.
00-3
WB97R-2
IMPORTANT SAFETY NOTICE
Proper service and repair is extremel important for the safe operation of our machine.
The service and repair techniques recommended b FKI and describe in this manual are both effective
and safe methods of operation. Some of these operations require the use of tools speciall designed b
FKI for the purpose.
To prevent injur to workers, the s mbols and are used to mark safet precautions in this man-
ual. The cautions accompan ing these s mbols should alwa s be carefull followed. If an danger arises
or ma possibl arise, first consider safet , and take necessar steps to face.
SAFETY
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13. Before starting work, remove the leads from the
batter . Alwa s remove the lead from the negative
( ± ) terminal first.
14. When raising heav components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Alwa s use lifting equipment which has ample ca-
pacit . Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowl to prevent
the component from hitting an other part.
Do not work with an part still raised b the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, alwa s
leave two bolts in position on opposite sides.
Slowl release the pressure, then slowl loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring ma cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If an fuel or oil drips on to the floor,
wipe it up immediatel .
Fuel or oil on the floor can cause ou to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use onl the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace an damage parts with new
parts.
.When installing hoses and wires, be sure that
the will not be damaged b contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that the are not twisted. Damaged tubes are dan-
gerous, so be extremel careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctl tightened.
21. When assembling or installing parts, alwa s use
specified tightening torques.
When installing the parts which vibrate violentl or
rotate at high speed, be particular careful to
check that the are correctl installed.
22. When aligning two holes, never insert our fingers
or hand.
23. When measuring h draulic pressure, check that
the measuring tool is correctl assembled before
taking an measurement.
24. Take sure when removing or installing tracks of in
particular rubber tracks. When removing the
track, the track separates suddenl , so never let
an one stand at either end of the wheel.
00-4
WB97R-2
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00-5
WB97R-2
FOREWORD
This shop manual has been prepared as an aid to improve the qualit of repairs b giving the operator an ac-
curate understanding of the product and b showing him the correct wa to perform repairs and make judgements.
Make sure ou understand the contents of this manual and use it to full effect at ever opportunit .
This shop manual mainl contains the necessar technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into
the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not onl to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This sections explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs.
Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The spe ifi ations ontained in this shop manual are subje t to hange at any time and without any
noti e.
Conta t your FKI distributor for the latest information.
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VOLUMES
Shop manual are issued as a guide to carr out re-
pairs. These various volumes are designed to avoid
duplicating the same information.
DISTRIBUTION AND UPDATING
An additions, amendments or other changes will
be sent to FKI distributors.
Get the most up-to-date information before ou start
an work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show ou how to read the
page number.
Example
3. Additional pages: additional pages are indicated
b a h phen (-) and number after the page num-
ber.
Fle as in the example.
Example:
10-4
10-4-1
10-4-2
10-5
]Added pages
REVISED EDITION MARK
(123....)
When a manual is revised, an edition mark is re-
corded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF RE-
VISED PAGES between the title page and SAFETY
page.
SYMBOLS
In order to make the shop manual greatl chelpful,
important points about safet and qualit are marked
with the following s mbols.
S mbol Item Remarks
Safet
Special safet precautions are ne-
cessar when performing the
work.
Extra special safet precautions
are necessar when performing
the work because it is under inter-
nal pressure.
Caution
Special technical precautions or
other precautions for preserving
standards are necessar when
performing the work.
Weight
Weight of parts or s stems.
Caution necessar when selecting
hoisting wire, or when working
posture is important, etc.
Tightening
torque
Parts that require special attention
for the tightening torque during as-
sembl .
Coat Parts to be coated with adhesives
and lubricants etc.
Oil, water Places where oil, water or fuel
must be added, and their quantit .
Drain
Places where oil or water must be
drained, and quantit to be
drained.
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
00-6
WB97R-2
Item number (10. Structure and
Function)
Consecutive page number for eac
h
item.
10 - 3
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