Komatsu WH Series Telescopic Handler Service Repair Shop Manual - WEBM005700

This Complete Service Repair Workshop Manual PDF Download for the WH609-1, WH613-1, WH713-1, WH714-1, WH714H-1, WH716-1 Komatsu Telescopic Handler has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu WH609-1 Telescopic Handler
Serial Numbers : 395F60001 and up

Komatsu WH613-1 Telescopic Handler
Serial Numbers : 395F60003 and up

Komatsu WH713-1 Telescopic Handler
Serial Numbers : 395F70001 and up

Komatsu WH714-1 Telescopic Handler
Serial Numbers : 395F70002 and up

Komatsu WH714H-1 Telescopic Handler
Serial Numbers : 395F70003 and up

Komatsu WH716-1 Telescopic Handler
Serial Numbers : 395F70004 and up


TABLE OF CONTENTS :

10. STRUCTURE AND FUNCTION
20. TESTING AND ADJUSTING
30. DISASSEMBLY AND ASSEMBLY
90. OTHER


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : WEBM005700
Total Pages : 516


This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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CONTENTS
REVISED PAGES
SAFETY
FOREWORD
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
STANDARD TIGHTENING TORQUE
COATING MATERIALS
ELECTRIC
WEIGHT TABLE
TABLE OF OIL AND COOLANT QUANTITIES
CONVERSION TABLE

10 STRUCTURE AND FUNCTION
ENGINE-TRANSMISSION COUPLING
POWER TRAIN
TRANSMISSION
FRONT AXLE
REAR AXLE
BRAKE PUMPS
STEERING SYSTEM (4WS)
STEERING UNIT
HYDRAULIC DIAGRAM
HYDRAULIC PUMP
CONTROL VALVE
PPC VALVE
SOLENOID VALVES
SAFETY VALVES
CYLINDERS
AIR CONDITIONING SYSTEM
CLIMATE CONTROL SYSTEM OPERATION
ELECTRICAL DIAGRAMS
FUSE CENTRE
CAB WIRING (1/2)
CAB WIRING (2/2)
CAB WIRING DIAGRAM (see also Group 90)
CAB ROOF WIRING
CAB ROOF WIRING DIAGRAM
ENGINE WIRING
ENGINE WIRING DIAGRAM
FRONT WIRING
FRONT WIRING DIAGRAM
REAR FRAME WIRING
REAR FRAME WIRING DIAGRAM
FRONT SERVICE LIGHTS WIRING
GROUND WIRING

20 TESTING AND ADJUSTMENTS
STANDARD SPECIFICATIONS
. ASPIRATED ENGINES
. TURBO ENGINES
. MACHINE MODELS WH609 - WH613 WITH ASPIRATED ENGINE
. MACHINE MODELS WH609 - WH613 WITH TURBO ENGINE
. MACHINE MODELS WH713 - WH714 - WH714H - WH716
. MACHINE MODEL WH609-1
. MACHINE MODEL WH613-1
. MACHINE MODEL WH713-1
. MACHINE MODEL WH714-1
. MACHINE MODEL WH714H-1
. MACHINE MODEL WH716-1
INTRODUCTION
VALVE LASH ADJUSTMENT
CHECKING ENGINE SPEED
. CHECKING THE ENGINE WITH NO LOAD
. CHECKING THE ENGINE UNDER LOAD
. ANALYSIS
TENSIONING THE AIR CONDITIONER COMPRESSOR BELT.
ADJUSTING ACCELERATOR CABLE LENGTH
ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING THE STOP LAMP MICROSWITCHES
. Checking procedure
. Pedal height adjustment
. Sprag length adjustment
. Microswitch adjustment
ADJUSTING THE PARKING BRAKES
. Brake cable length adjustment.
. Functional check
BLEEDING AIR FROM CIRCUITS
. Pump housing fill
. Bleeding air from cylinders
. Bleeding air from brake circuits
PREPARING THE MACHINE READY FOR HYDRAULIC PRESSURE CHECK AND CALIBRATION
CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC PRESSURES
FOREWORD
1. CALIBRATION CHECK GENERAL VALVE (Cut-off valve)
2. SECONDARY VALVE CALIBRATION CHECK
. Boom lift and extension
. Equipment dump and curl
3. GENERAL AND SECONDARY VALVE CALIBRATION
4. SERVOCONTROL PRESSURE CHECK
5. CHECKING STEERING PRESSURE AND PRIORITY VALVE OPERATION
. LS signal check
. Inspection of priority valve operation
CALIBRATING THE PRESSURE OF THE STEERING SYSTEM
. Checking procedure
. Calibration procedure
INSPECTING THE OPERATION OF THE UNLOADING VALVE
CHECKING AND CALIBRATING THE DR VALVE (PUMP FLOW VARIATION)
. Checking procedure
. Calibration procedure
CHECKING THE DYNAMIC PUMP DP VALUE
CHECKING PUMP FLOW
BRAKE SYSTEM CHECKS
. Inspecting the circuit and brake pumps for leaks.
. Inspecting the brake units for leaks
TRANSMISSION (POWER SHIFT) CHECKS
TROUBLESHOOTING GUIDE
. Low clutch pressure
. Low feed pressure
. Overtemperature
. Noisy converter
. Poor power
TRANSMISSION ASSEMBLY PRESSURE CHECKS
1. General converter pressure
2. Engagement pressure for each individual clutch
3. Inspecting the 1st clutch - forward and reverse gear
4. Inspecting the 2nd - 3rd - 4th clutch
5. Transmission clutch wear inspection
CHECKING THE SPEED OF THE TRANSMISSION SHAFTS RESPONSIBLE FOR TRANSLATION (CARDAN SHAFTS)
LEVEL CALIBRATION
CHECKING LOAD CELL CALIBRATION
1. Checking load signal with no load
2. Checking load signal in turnover conditions
CALIBRATING THE OVERTURN PREVENTION SYSTEM (SAR)
. Calibration conditions:
. Calibration procedure
. Error coding
CHECKING WEIGHT PERCENTAGE ON REAR AXLE
. Preparing the machine ready for the inspection
CHECKING SHOE CLEARANCE
1. Intermediate boom front shoe clearance
CHECKING BOOM SIDE ALIGNMENT
BOOM CHAINS
. Oxidation inspection
. Chain re-lubrication procedure
CHAIN TENSIONING
. Preparation
1. Retraction chains:
. Checking procedure
. Adjustment procedure
2. Extension chains
. Checking procedure
. Adjustment procedure
3. Checking chain stretch
4. Final checks
CHECKING FOR BLOW-BY
ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT
1. Checking procedure for stabilizers (if equipped)
2. Checking procedure for equipment cylinder
3. Checking procedure for the boom lift cylinder
4. Checking procedure for the boom extension cylinder
5. Checking procedure for the frame levelling cylinder
6. Checking procedure for axle locking cylinder
EQUALIZING STABILIZER SPEED
AIR CONDITIONING SYSTEM MAINTENANCE
. Emptying and filling the air conditioning system
CHECKING THE A/C SYSTEM’S OPERATING TEMPERATURE
. Checking the A/C system

30 REMOVAL AND INSTALLATION
HOW TO READ THE MANUAL
PRECAUTIONS TO BE TAKEN WHEN WORKING
SPECIAL TOOLS
ENGINE HOOD
Removal
Installation
AIR FILTER
Removal
Installation
TURBOCOMPRESSOR (only if equipped)
Removal
Installation
EXHAUST PIPE
Removal
. 1st Length
. 2nd Length
Installation
GENERATOR - FAN BELT
Removal
Installation
RADIATOR-EXCHANGER ASSEMBLY
Removal
Installation
MUFFLER
Removal
Installation
BATTERY - BATTERY TRAY
Removal
. Battery
. Battery tray
Installation
CYLINDER HEAD
Removal
Installation
INJECTORS
Removal
Installation
INJECTION PUMP
Removal
Installation
HYDRAULIC PUMP
Removal
Installation
COMPLETE ENGINE- SHIFT ASSEMBLY
Removal
Installation
ENGINE-TRANSMISSION
Detachment
Joining
CONTROL VALVE ASSEMBLY
Removal
Installation
BRACKET CONTROL, EQUIPMENT LOCK, AND FRAME LEVELLING SOLENOID VALVES
Removal
Installation
AIR CONDITIONER COMPRESSOR (only if equipped)
Removal
Installation
AIR CONDITIONER COMPRESSOR BELT
Removal
Installation
SERVO-CONTROL FEED VALVE
Removal
Installation
STEERING SELECTION SOLENOID VALVE ASSEMBLY
Removal
Installation
FRONT AXLE
Preparation
. Machine with outriggers
. Machine without outriggers
Removal
Installation
REAR AXLE
Preparation
. Machine with outriggers
. Machine without outriggers
Removal
Installation
TELESCOPIC BOOM
Removal
Installation
LIFT AND OFFSET CYLINDERS
Removal
Installation
INTERMEDIATE AND TOP BOOM
Removal
Installation
EXTENSION CYLINDER
Removal
Installation
BOOM SLIDING SHOES
Replacement
1. Lower shoes for intermediate and top booms.
2. Upper shoes for intermediate boom.
3. Side shoes for intermediate and top boom.
4. Upper shoes for top boom.
5. Rear upper shoes for intermediate boom
6. Rear upper shoes for top boom
7. Rear lower shoes for intermediate and top boom.
EXTENSION AND RETRACTION CHAINS (Versions with 3-section boom)
Removal
Installation
CHAIN RETURN PULLEY PINS AND BUSHINGS
RETRACTION CHAIN PULLEY
Removal
Installation
EXTENSION CHAIN PULLEYS
Removal
Installation
LOAD CELL
Installation
CONTROL UNIT
Removal
Installation
BALLAST
Removal
Installation
ENGINE LINE CENTRE
Removal
Installation
ACCELERATOR CABLE
Removal
Installation
SHIFT-REVERSING GEAR LEVER ASSEMBLY
Removal
Installation
STEERING COLUMN SWITCH UNIT - DIPSWITCH
Removal
Installation
STEERING UNIT
Removal
Installation
Disassembly
. Removing the seals
. Removing the wiper ring
Assembly
. Installing the inner seal (15)
. Installing the control valve
. Completing the installation procedure
STEERING COLUMN
Removal
Installation
BRAKE PUMPS
Removal
Installation
PPC VALVE
Removal
Installation
LEVEL
Removal
Installation
WIPER MOTORS
Removal
. Front wiper motor
. Rear wiper motor
. Upper wiper motor
Installation
PARKING BRAKE CABLE
Removal
Installation
DASH / INSTRUMENT PANEL
Removal
Installation
CONTROL PANEL
Removal
Installation
FUSE AND RELAY CENTRE
Removal
Installation
PROPELLER SHAFT
Removal
. Front cardan shaft
. Rear cardan shaft
Installation
FUEL TANK
Removal
Installation
HYDRAULIC OIL TANK
Removal
Installation
FRAME LEVELLING CYLINDER
Removal
Installation
FRAME SWING LOCKING ROD (WH609 and WH613 only)
Removal
Installation
AXLE LOCKING CYLINDER
Removal
Installation
STABILIZER CYLINDERS (If equipped)
Removal
Installation
EQUIPMENT HOLDER
Removal
Installation
EQUIPMENT MOTION CYLINDER
Removal
Installation
CYLINDERS
Disassembly
Assembly
EQUIPMENT QUICK-LOCK ASSEMBLY
Removal
Installation
AIR CONDITIONER FANS
Removal
Installation
AIR CONDITIONER CONDENSER ASSEMBLY
Removal
Installation
DEHUMIDIFYING FILTER
Removal
Installation
PAIR CONDITIONING SYSTEM PRESSURE SWITCH
Removal
Installation
CAB
Removal
Installation
TRANSMISSION
TRANSMISSION ASSEMBLY
Disassembly
Assembly
1st CLUTCH
Disassembly
Assembly
2nd CLUTCH
Disassembly
Assembly
4th CLUTCH
Disassembly
Assembly
3rd CLUTCH
Disassembly
Assembly
REVERSE CLUTCH
Disassembly
Assembly
FORWARD CLUTCH
Disassembly
Assembly
PRESSURE REGULATOR VALVE
Disassembly
Assembly
MODULATED VALVE
Disassembly
Assembly
SPACER PLATE
Disassembly
Assembly
CONVERTER HOUSING
Disassembly
Assembly
DROP BOX ASSEMBLY
Disassembly
. Complete drop box assembly
. Input shaft
Assembly
. Input shaft
. Complete drop box assembly
AXLES
Disassembly
. Planetary reduction
. Steering case
. Cardan shaft
. Brakes
. Parking brake assembly (front axle)
. Removal of steering cylinder
. Disassembly of steering cylinder
. Differential
. Bevel pinion
ASSEMBLY
. Bevel pinion
. Differential
. Steering cylinder
. Steering cylinder
. Convergency adjustment
. Parking brake assembly (front axle)
. Brakes
. Cardan shaft
. Steering case
. Planetary reduction

90 OTHERS
CAB WIRING
ELECTRICAL DIAGRAM

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