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Komatsu WD900-3 Wheel Dozer Service Repair Manual (SN 50001 and up)

Service Repair Manual

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Komatsu WD900-3 Wheel Dozer Service Repair Manual (SN 50001 and up)

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  1. SEBM036901 MACHINE MODEL SERIAL NUMBER WD900-3 50001 and up • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • WD900-3 mount the SA12V140-1 engine. For details of the engine, see the 12V140 Series Engine Shop Manual. © 2004 All Rights Reserved Printed in Japan 07-04 (01) 00-1 (1)

  2. GENERAL CONTENTS No. of page 01 GENERAL............................................................................................................................ 01-1 10 STRUCTURE AND FUNCTION ................................................................ 10-1 20 TESTING AND ADJUSTING ........................................................................ 20-1 30 DISASSEMBLY AND ASSEMBLY....................................................... 30-1 40 MAINTENANCE STANDARD ..................................................................... 40-1 90 OTHERS ................................................................................................................................ 90-1 00-2 (1) WD900-3

  3. 01 GENERAL GENERAL ASSEMBLY DRAWING ..............................................................................................................01- 2 SPECIFICATIONS ........................................................................................................................................01- 3 WEIGHT TABLE............................................................................................................................................01- 6 LIST OF LUBRICANT AND WATER.............................................................................................................01- 8 01-1 WD900-3

  4. GENERAL GENERAL ASSEMBLY DRAWING GENERAL ASSEMBLY DRAWING 01-2 WD900-3

  5. GENERAL SPECIFICATIONS SPECIFICATIONS Machine model WD900-3 Serial No. 50001 and up Operating weight kg 100,000 Weight Distribution (front) kg 50,000 Distribution (rear) kg 50,000 Blade capacity m3 26.0 FORWARD 1st km/h 7.0 FORWARD 2nd km/h 12.3 FORWARD 3rd km/h 28.0 Travel speed Performance REVERSE 1st km/h 7.1 REVERSE 2nd km/h 12.4 REVERSE 3rd km/h 28.3 Max. rimpull kN {kg} 686.5 {70,000} Gradeability deg 25 Center of outside wheel mm 9,200 Min. turning radius Outside portion of blade mm 11,285 Overall length mm 12,035 Overall width without blade mm 4,585 Blade width mm 6,470 Dimensions Blade height mm 2,160 Overall height (top of ROPS cab) mm 5,215 Wheelbase mm 5,450 Tread mm 3,350 Min. ground clearance mm 480 01-3 WD900-3

  6. GENERAL SPECIFICATIONS Machine model WD900-3 Serial No. 50001 and up Model SA12V140-1 4-cycle, water-cooled, V type, 12-cylinder direct injection, with 2-turbocharger, after-cooler Type No. of cylinders - bore x stroke mm 12 – 140 x 165 l {cc} Piston displacement 30.48 {30,480} Flywheel horsepower kW/rpm {HP/rpm} 637/2,000 {853/2,000} Engine Maximum torque Nm/rpm {kgm/rpm} 4,090/1,300 {417/1,300} Performance Fuel consumption ratio g/kWh {g/HPh} 200 {145} High idling speed rpm 2,220 Low idling speed rpm 650/850 Starting motor 24 V, 7.5 kW x 2 Alternator 24 V, 75 A Battery 12 V, 200 Ah x 4 3-element, 1-stage, single-phase (TCA51-1A) Torque converter Power train Planetary gear, multiple-disc, hydraulically actuated, modulation type Transmission Reduction gear Spiral bevel gear Differential Straight bevel gear Final drive Planetary gear, single reduction, oil bath Drive type Front/rear-wheel drive Front axle Fixed-frame, full-floating Axle, wheel Rear axle Center pin support type, full-floating Tire 45/65 R45 XLDD1 (L-4) Wheel rim 36.00 x 45WTB Inflation pressure kPa {kg/cm2} 667 {6.80} Front/rear wheel braking, separate front/rear wheel, wet disc, hydraulically actuated Main brake Brakes Mounted on front axle input shaft, dry disc, hydraulically release spring apply Parking brake 01-4 WD900-3

  7. GENERAL SPECIFICATIONS Machine model WD900-3 Serial No. 50001 and up Type Articulated type Steering system Structure Fully hydraulically power steering 421 l/min Torque converter, transmission pump (Gear type: SAR(4)112+SAR(3)100) 307 l/min Steering pump (Fixed capacity piston pump: HPF76+71) 405 l/min Switch pump (Fixed capacity piston pump: HPV95+95) Additional oil cooler fan pump 51 l/min Hydraulic pump (Gear type: SAR(1)025) delivery 67.8 l/min Front brake cooling pump (Gear type: SBL(1)24) 67.8 l/min Rear brake cooling pump (Gear type: SBR(1)24) 68 l/min PPC pump (Gear type: SAR(1)032) Hydraulic system 29 l/min Brake pump (Gear type: SAR(1)014) 405 l/min Work equipment pump (Variable capacity piston pump: HPV90+90) 2.5 {25} Transmission valve MPa {kg/cm2} (Spool type, electric control) Control valve Set pressure 31.4 {320} Steering demand valve MPa {kg/cm2} (Fully hydraulic type) 3.7 {38} (2-lever type) PPC valve MPa {kg/cm2} 31.4 {320} (2-spool type) Main control valve MPa {kg/cm2} Reciprocating piston 1 – 160 x 503 Steering cylinder No. - bore x stroke mm Cylinder Reciprocating piston 1 – 200 x 1,300 Lift cylinder No. - bore x stroke mm Reciprocating piston 2 – 225 x 240 Tilt cylinder No. - bore x stroke mm equipment Blade type Semi U-blade Work Blade frame type Outer frame 01-5 WD900-3

  8. GENERAL WEIGHT TABLE WEIGHT TABLE k This weight table is a guide for use when transporting or handling components. Unit: kg Machine model WD900-3 Serial No. 50001 and up Engine 3,200 Radiator 1,200 Torque converter 590 Transmission 2,300 Damper 178 Upper drive shaft 68.5 Center drive shaft 190 Front drive shaft 180 Rear drive shaft 190 Center support 154 Front axle 8,190 Rear axle 7,700 Front differential assembly 1,226 Rear differential assembly 1,256 Planetary carrier assembly (each) 238 Planetary hub assembly (each) 600 Axle pivot (Rear axle) 286 Wheel (each) 845 Tire (each) 2,130 Steering demand valve 58 Steering cylinder (each) 203 Hydraulic tank 823 Work equipment pump 167 Parking brake assembly 185 Torque converter charging + PPC + brake pump 49 Switch pump 141 Switch + additional oil cooler fan pump 151 Steering pump 141 Fender and guard assembly 1,393 PPC valve 5.5 Main control valve (each) 95 DC · CO valve 90 Lift cylinder (each) 621 Tilt cylinder 598 Fender and ladder assembly 1,720 01-6 WD900-3

  9. GENERAL WEIGHT TABLE Unit: kg Machine model WD900-3 Serial No. 50001 and up 88 (Top) 28 (Side) Engine hood Front frame 9,966 Rear frame 9,855 Outer frame (L.H.) 1,136 Outer frame (R.H.) 1,148 H linkage 1,408 Y linkage 1,338 Support (L.H.) 1,909 Support (R.H.) 1,913 Blade 7,149 Counterweight 2,900 Fuel tank 780 Battery (each) 59 Cab 430 Air conditioner unit 55 Operator’s seat 48 Floor plate 348 ROPS support assembly 1,387 01-7 WD900-3

  10. GENERAL LIST OF LUBRICANT AND WATER LIST OF LUBRICANT AND WATER Note 1: For axle oil, use only recommended oil as follows. SHELL : DONAX TD MOBILE : MOBILFLUID 424 ESSO : TORQUE FLUID 56 It is possible to substitute engine oil CLASS-CD SAE30 for axle oil. If noise comes from the brake, it is no problem of durability. a In cold areas when the hydraulic oil temperature is low, if the steering wheel is turned and the machine is stopped in that position, there may be a time lag before the machine turns and stops. If this happens, turn the steering wheel slowly to the left and right (repeat for about 10 minutes) and the oil inside the steering valve will be warmed up. *1: [When working in particularly severe conditions, use a multi-purpose grease containing 3 – 5% molybde- num. *2: For machines equipped with an auto-grease system, if the machine is operated in temperatures below –20°C, use lithium-based grease No. 0 for the grease. 01-8 WD900-3

  11. GENERAL LIST OF LUBRICANT AND WATER REMARK • When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic mainte- nance hours described in this manual. • Change oil according to the following table if fuel sulphur content is above 0.5%. Change interval of oil in engine oil pan 1/2 of regular interval 1/4 of regular interval Fuel sulphur content 0.5 to 1.0 % Above 1.0 % • When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric tem- perature goes up to 10°C more or less in the day time. • Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. • There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table. • We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. • Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill sys- tem during normal inspection and maintenance. • ASTM: American Society of Testing and Material SAE : Society of Automotive Engineers API : American Petroleum Institute 01-9 WD900-3

  12. DISASSEMBLY AND ASSEMBLY STARTING MOTOR REMOVAL AND INSTALLATION OF STARTING MOTOR INSTALLATION • Carry out installation in the reverse order to removal. REMOVAL k Disconnect the cable from the negative (–) ter- minal of the battery. 1. Remove side cover (1). 2. Remove fuel control lever (2) together with bracket (3). 3. Disconnect connectors (4) (ER1, 2, 3). 4. Disconnect connectors (5) (ER06, 07). 5. Disconnect cables (6) and (7). 6. Remove starting motors (8) and (9). 30-21 (1) WD900-3

  13. DISASSEMBLY AND ASSEMBLY ALTERNATOR REMOVAL AND INSTALLATION OF ALTERNATOR INSTALLATION • Carry out installation in the reverse order to removal. REMOVAL k Disconnect the cable from the negative (–) ter- minal of the battery. 3 Terminal mounting nut: Terminal R: 1.9 – 2.5 Nm {0.19 – 0.25 kgm} Terminal E: 3.2 – 4.4 Nm {0.33 – 0.45 kgm} Terminal B: 16.1 – 22.1 Nm {1.65 – 2.25 kgm} [*1] 1. Open side cover (1). 3 Lock bolt: [*2] 54 – 123 Nm {5.5 – 12.5 kgm} [*3] a Adjust the deflection of the belt to the speci- fied dimension. For details, see TESTING AND ADJUSTING, Testing and adjusting al- ternator belt tension. 2. Disconnect connectors (2) (E20, 21, 22). [*1] 3. Loosen locknuts (3). 4. Remove lock bolt (4). 5. Remove lock bolt (5) and turn down adjustment bolt (6) toward the air conditioner compressor. [*2] 6. Loosen the alternator mounting bolt, then remove drive belt (7). [*3] 7. Remove the mounting bolt, then remove alterna- tor (8). 30-22 (1) WD900-3

  14. DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER REMOVAL AND INSTALLATION OF ENGINE OIL COOLER INSTALLATION • Carry out installation in the reverse order to removal. REMOVAL [*1] 1. Open the left cover. a Install fuel injection pump for right bank ac- cording to REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP FOR RIGHT BANK. 2. Loosen radiator drain valve and drain cooling water. a If the coolant contains antifreeze, dispose of it correctly. a Tighten drain valve and add water to the specified level, and then run the engine to circulate the water then check the water level of reservoir tank. 3. Remove fuel injection pump (1) assembly for right bank. a For details, see REMOVAL AND INSTALLA- TION OF FUEL INJECTION PUMP FOR RIGHT BANK (WITHOUT GOVERNOR). [*1] 4. Remove front oil cooler assembly (2). 5. Remove rear oil cooler assembly (3). 30-23 (1) WD900-3

  15. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR LEFT BANK REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP FOR LEFT BANK (WITH GOVERNOR) 9. Remove coupling lock bolt (9). REMOVAL k Close valve between fuel tank and fuel filter. 1. Open left side cover. 2. Remove cover (1). DEW3906 3. Remove control rods (2). 10. Remove mounting bolts, then remove fuel injec- tion pump. a When removing fuel injection pump, be care- ful not to drop the key. 4 Fuel injection pump: 30 kg 4. Disconnect injection pump lubrication tubes (3). 5. Disconnect fuel hoses (4). 6. Disconnect air tube (5). 7. Disconnect fuel injection tubes (6). [*1] INSTALLATION • Carry out installation in the reverse order to removal. 3 Sleeve nut: 24 ± 1 Nm {4 ± 0.1 kgm} a Check fuel injection timing according to TESTING AND ADJUSTING FUEL INJEC- TION TIMING. [*1] 8. Remove mounting bolts at injection pump end to remove rack control rod (7). 30-24 (1) WD900-3

  16. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR RIGHT BANK REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP FOR RIGHT BANK (WITHOUT GOVERNOR) 7. Remove coupling lock bolts (6). REMOVAL k Close valve between fuel tank and fuel filter. 1. 1.Open left side cover. 2. Remove lower cover (1) of coupling part. 3. Disconnect injection pump lubrication tubes (2). 8. Remove mounting bolts, then remove fuel injec- tion pump. a When removing the fuel injection pump, be careful not to drop key. 4 Fuel injection pump: 23 kg 4. Disconnect fuel hoses (3). 5. Disconnect fuel injection tubes (4). [*1] INSTALLATION • Carry out installation in the reverse order to removal. 3 Sleeve nut: 24 ± 1 Nm {2.4 ± 0.1 kgm} a Check fuel injection timing according to TESTING AND ADJUSTING FUEL INJEC- TION TIMING. [*1] 6. Remove mounting bolts at injection pump end to remove rack control rod (5). 30-25 (1) WD900-3

  17. DISASSEMBLY AND ASSEMBLY WATER PUMP REMOVAL AND INSTALLATION OF WATER PUMP INSTALLATION • Carry out installation in the reverse order to removal. REMOVAL a Tighten drain valve and add water to speci- fied level, and then run the engine to circu- late water, then check water level of reservoir tank. 1. Open left side cover. 2. Loosen drain valve and drain cooling water. a If cooling water contains antifreeze, dispose of it correctly. 3. Remove cover (1). 4. Remove corrosion resistor (2). 5. Disconnect hoses (3). 6. Disconnect bypass pipe (4). 7. Remove water pump (5). 4 Water pump: 22 kg 30-26 (1) WD900-3

  18. DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER REMOVAL AND INSTALLATION OF NOZZLE HOLDER 5. Fully screw forcing screw [1] (10 mm, P = 1.5) in the nozzle holder, then pull out nozzle holder (8) by levering it up with a bar. a When pulling out the nozzle holder, clean around it so that foreign matter will not enter the empty hole. a Check that the gasket is fitted to the nozzle end. REMOVAL k Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the ma- chine from moving. 1. Remove the engine hood. 2. emove head cover mounting bolt (1), then remove head cover (2). [*1] 3. Remove lock nut (4), then pull out connection (5). [*2] 4. Remove bolt (6), then remove holder (7). [*3] INSTALLATION • Carry out installation in the reverse order to removal. 3 Head cover mounting bolt: [*1] 3.9 ± 0.1 Nm {0.4 ± 0.1 kgm} 3 Connection: 37 ± 3 Nm {3.8 ± 0.3 kgm} 3 Lock nut: 39 ± 5 Nm {4.0 ± 0.5 kgm} [*2] 3 Bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} [*3] 30-27 (1) WD900-3

  19. DISASSEMBLY AND ASSEMBLY TURBOCHARGER REMOVAL AND INSTALLATION OF TURBOCHARGER 10. Disconnect lubrication oil inlet hoses (11). 11. Disconnect lubrication oil outlet hoses (12). REMOVAL k Stop the machine on level ground and lower the work equipment completely to the ground. k Disconnect the cable from the negative (–) ter- minal of the battery. 12. Remove the mounting bolts or nuts, then remove turbochargers (13). 4 Turbocharger: 22 kg (1 piece) [*1] 1. Remove mufflers (1). 2. Remove handrail (2). 3. Sling and remove engine hood (3). INSTALLATION • Carry out installation in the reverse order to removal. [*1] a Replace the removed gaskets with new gas- kets. 3 Mounting bolt: 49 ± 5 Nm {5.0 ± 0.5 kgm} 4. Disconnect air cleaner connecting hose. 5. Disconnect Komaclone tubes (5). 6. Remove mufflers (6). 7. Disconnect connectors (7). 8. Remove bolts (8), then remove exhaust elbows (9). a Check the number of the shims. 9. Remove elbows (10). a Check the number of the shims. 30-28 (1) WD900-3

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  21. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL INSTALLATION 1. Front oil seal and sleeve 1) When the seal contact face of the crank- shaft is not worn • Press fit the oil seal to the end of the gear case cover by 11mm with tool A2 a Fill the space between lips on the out- side with grease (G2-LI) up to 50 – 80%. a Tighten the mounting bolts evenly. 2) When the seal contact face of the crank- shaft is worn • If the position of the oil seal can be changed, press fit a new oil seal to a place at which its lip does not touch the worn groove. a Measure the position of the worn groove, then press fit the new oil seal with tool A2 to a place where there is not a worn groove. SPECIAL TOOLS New/remodel Necessity Symbol Sketch Q'ty Part No. Part Name t t t t t t 795-602-2200 Installer KIT 1 1 1 1 6 6 • 795-602-2210 • Installer • 795-502-2220 • Installer A 2 • 01050-32250 • Bolt • 01050-32240 • Bolt • 01640-22232 • Washer REMOVAL 1. Remove the radiator. For details, see REMOVAL AND INSTALLATION OF RADIATOR. 2. Remove mounting bolts (1), then remove damper and crank pulley (2). 3) When the position of the oil seal cannot be changed • Press fit sleeve (5) to the crankshaft. a Remove rust and mud from sleeve fitting portion of the crankshaft. a Thinly apply sealant (LG-7) over the inside of sleeve (5), then install the sleeve to the end of crankshaft (3) in parallel by hitting it lightly with a wooden or plastic hammer. 3. Take care not to damage crankshaft (3), remove seal (4) with a screwdriver, etc. 30-29 (1) WD900-3

  22. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL 2. Install damper and crank pulley (2). Tighten mounting bolts (1) in the order given in the diagram below. a Apply engine oil (SAE-30CD) to the mount- ing bolts. 3 Mounting bolt 1st step: 74 ± 20 Nm {7.5 ± 2.0 kgm} 2nd step: 245 – 20 Nm {25 ± 2 kgm} 3rd step: 745 – 20 Nm {76 ± 2 kgm} a If the mounting bolts are tightened with an impact wrench, their threads may be broken. Accordingly, tighten them with a hand tool. a Press fit the sleeve to the depth of 5mm from the crankshaft end with tool A2 a Press fit the sleeve by tightening the bolts alternately. Press fit the seal. a Fill the space between lips on the out- side with grease (G2-LI) up to 50 – 80%. a Press fit front seal (6) to the depth of 13mm with tool A2 • 30-30 (1) WD900-3

  23. DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL REMOVAL AND INSTALLATION OF ENGINE REAR SEAL INSTALLATION 1. Rear oil seal and sleeve 1) When the seal contact face of the crank- shaft is not worn • Press fit the oil seal to the crankshaft end by 21mm with tool A3 a Fill the space between lips on the out- side with grease (G2-LI) up to 50 – 80%. a Tighten the mounting bolts evenly. SPECIAL TOOLS New/remodel Necessity Symbol Sketch Q'ty Part No. Part Name t t t t t t 10 q 795-602-2300 Installer KIT 1 1 1 5 5 2) When the seal contact face of the crank- shaft is worn • If the position of the oil seal can be changed, press fit a new oil seal to a place at which its lip does not touch the worn groove. a Measure the position of the worn groove, then press fit the new oil seal with tool A3 to a place where there is not a worn groove. • 795-602-2320 • Installer • 795-502-2120 • Sleeve 3 A • 01050-32055 • Bolt • 01050-22040 • Bolt • 01640-22032 • Washer 4 795-931-1100 Puller 1 REMOVAL 1. Remove the torque converter and transmission. For details, see REMOVAL AND INSTALLA- TION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY. 2. Remove mounting bolts (1), then remove fly- wheel (2). 3) When the position of the oil seal cannot be changed • Press fit sleeve (5) to the crankshaft. a Remove rust and mud from sleeve fitting portion of the crankshaft. a Thinly apply sealant (LG-7) over the in- side of sleeve (5), then install the sleeve to the end of crankshaft (3) in parallel by hitting it lightly with a wooden or plastic hammer. a Press fit the sleeve to the depth of 14 mm from the crankshaft end with tool A3 a Press fit the sleeve by tightening the bolts alternately. 3. Taking care not to damage crankshaft (3), remove seal (4) with a screwdriver, etc. 30-31 (1) WD900-3

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