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KOMATSU WA65-5 WA70-5 WA80-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 & UP) KOMATSU WA65-5 WA70-5 WA80-5 – PDF DOWNLOAD
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- KOMATSU WA65-5 WA70-5 WA80-5 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:H50051 & UP
- PUBLICATION NUMBER:VEBM250100
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Description
KOMATSU WA65-5 WA70-5 WA80-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 & UP) KOMATSU WA65-5 WA70-5 WA80-5
KOMATSU WA65-5 WA70-5 WA80-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 & UP) KOMATSU WA65-5 WA70-5 WA80-5 – PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU WA65-5 WA70-5 WA80-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 & UP) KOMATSU WA65-5 WA70-5 WA80-5
VEBM250100_WA65-5_WA80-5_Shop_Manual.................................................... 1 SAFETY.................................................................................. 3 Safety notice....................................................................... 5 Preparations for work........................................................... 6 Tipping up the driver's cab..................................................... 6 Tipping down the driver's cab................................................... 9 Precautions during work......................................................... 10 Foreword............................................................................ 13 How to read the shop manual......................................................... 14 Volumes......................................................................... 14 Distribution and updating....................................................... 14 Filing method................................................................... 14 Symbols......................................................................... 15 Hoisting instructions............................................................... 16 Wire ropes...................................................................... 16 GENERAL................................................................................. 19 Dimensions, weights and operating data WA65-5....................................... 21 Specifications WA65-5............................................................... 22 Weight table WA65-5................................................................. 23 Dimensions, weights and operating data WA70-5....................................... 24 Specifications WA70-5............................................................... 25 Weight table WA70-5................................................................. 26 Dimensions, weights and operating data WA80-5....................................... 27 Specifications WA80-5............................................................... 28 Weight table WA80-5................................................................. 29 Lubricants and operating mediums: WA65-5/ WA70-5.................................... 30 Lubricants and operating mediums: WA80-5............................................ 31 Basic procedures of maintenance..................................................... 32 Oil............................................................................. 32 Fuel............................................................................ 32 Coolant......................................................................... 33 Grease.......................................................................... 33 Storing oil and fuel............................................................ 33 Filters......................................................................... 34 Biodegradable hydraulic oils and lubricants..................................... 34 Outline of electric system...................................................... 34 Torque list – screws and nuts....................................................... 35 STRUCTURE AND FUNCTION.................................................................. 37 Powertrain.......................................................................... 39 Closed circuit...................................................................... 40 Hydraulic drive system 20Km/h....................................................... 41 Hydraulic drive system 30Km/h....................................................... 42 Variable displacement pump.......................................................... 43 Regulating valve................................................................ 46 Charge pressure limiting valve.................................................. 46 Control cylinder................................................................ 47 4/3 Way valve with direction control solenoids.................................. 47 Pressure cut-off valve.......................................................... 48 Safety-/charge valve............................................................ 48 Towing.......................................................................... 49 Variable displacement motor......................................................... 50 Drive shaft......................................................................... 52 Axle mounting – front axle.......................................................... 53 Axle mounting – rear axle........................................................... 53 WA65-5 / WA70-5: Front axle......................................................... 54 With outer disc brake as service brake and parking brake........................ 54 WA80-5: Front axle.................................................................. 55 With inner disc brake as service brake and outer disc brake as parking brake.... 55 Rear axle with transfer box......................................................... 56 Transfer box TB172.................................................................. 57 Limited slip differential (locking value 25%)....................................... 58 Locking differential (locking value 100%)........................................... 60 Wheel hub, front and rear axle...................................................... 62 WA65-5 / WA70-5: Service and parking brake, front axle.............................. 63 WA80-5: Service brake, front axle................................................... 65 WA80-5: Parking brake, front axle................................................... 66 Sevice and parking brake circuit.................................................... 67 WA65-5 / WA70-5: Service brake assembly............................................. 68 WA80-5: Service brake assembly...................................................... 69 Inch-brake Valve.................................................................... 70 Steering articulation joint......................................................... 71 Steering system..................................................................... 72 Hydraulic circuit diagram of steering system.................................... 72 Priority valve.................................................................. 73 Orbit-roll-valve................................................................ 74 Steering relief valve........................................................... 75 Work equipment hydraulic WA65/WA70-5................................................ 76 Travel, steering and work hydraulics............................................ 76 Work equipment hydraulic WA80-5..................................................... 78 Travel, steering and work hydraulics............................................ 78 PPC-Valve........................................................................... 80 Operation of PPC-valve.......................................................... 81 Servo pressure regulating valve................................................. 82 Emergency Lowering System....................................................... 82 Main control valve.................................................................. 84 WA65-5 / WA70-5: Lift cylinder...................................................... 86 WA80-5: Lift cylinder............................................................... 87 Dump cylinder....................................................................... 88 Steering cylinder................................................................... 89 Lifting frame with quick-coupler.................................................... 90 Quick-coupler....................................................................... 91 Monitor display..................................................................... 92 Sensors............................................................................. 93 Engine oil pressure sensor...................................................... 93 Fuel level sensor............................................................... 94 Engine coolant temperature sensor............................................... 95 Brake oil reservoir sensor...................................................... 96 Ribbon heater....................................................................... 97 Engine stop / start / preheating circuit............................................ 98 Electrical fuses and relays.........................................................100 Fuses...........................................................................100 Relays..........................................................................101 Engine room.....................................................................102 Electrical diagrams.................................................................103 Wiring diagram 1/5 - foldout 90-9...............................................103 Wiring diagram 2/5 - foldout 90-11..............................................103 Wiring diagram 3/5 - foldout 90-13..............................................103 Wiring diagram 4/5 - foldout 90-15..............................................103 Wiring diagram 5/5 - foldout 90-17..............................................103 Speed control - foldout 90-19...................................................103 Immobilizer - foldout 90-21.....................................................103 Air conditioner (option)............................................................104 Introduction....................................................................104 Function........................................................................105 The coolant circuit.............................................................105 The condenser...................................................................107 The vaporizer...................................................................108 The filter dryer................................................................109 Installation of air conditioner.................................................111 Safety when handling coolants...................................................112 Operating the air conditioner...................................................114 Maintenance of the air conditioner..............................................115 Regular maintenance.............................................................116 Instructions for filling........................................................118 Exchange of magnetic clutch.....................................................121 Exchange of compressor..........................................................122 Troubleshooting.................................................................124 TESTING AND ADJUSTING...................................................................129 Standard value table for engine - WA65-5 / WA70-5 / WA80-5..........................131 Standard value table for chassis – WA65-5...........................................132 Standard value table for chassis – WA70-5...........................................134 Standard value table for chassis – WA80-5...........................................136 Standard value table for electrical parts...........................................138 Test certificate – WA65-5...........................................................139 Test certificate – WA70-5...........................................................140 Test certificate – WA80-5...........................................................141 Valve lash clearance................................................................142 Engine compression test.............................................................144 Injection nozzle pressure...........................................................145 Fuel injection timing...............................................................146 V-belt tension......................................................................148 Engine RPM..........................................................................149 RPM-dependant drive take-up.........................................................150 Engine stall torque RPM.............................................................151 Engine stall torque RPM, test with the hydrostatic drive.......................151 Engine stall torque RPM, test with hydrostatic drive and working hydraulics....152 Feed pump (and servo oil pressure for WA80-5).......................................153 Hydraulic pressure cut-off..........................................................154 Working hydraulic pressure..........................................................156 Steering oil pressure...............................................................157 Testing.........................................................................157 Adjusting.......................................................................158 Operating time for steering wheel...................................................159 Operating force of steering wheel...................................................159 Disc brake (foot brake WA80-5)......................................................160 Brake (WA65-5 and WA70-5)...........................................................160 Inch valve – basic adjustment.......................................................161 WA 65-5 and WA70-5..............................................................161 WA 80-5.........................................................................161 Brake efficiency....................................................................162 Measuring the stopping distance.................................................162 Parking brake efficiency............................................................163 Travel speed........................................................................164 DISASSEMBLY AND ASSEMBLY................................................................165 Comments............................................................................167 Starter assembly....................................................................168 Removal of starter assembly.....................................................168 Installation of starter assembly................................................169 Alternator assembly.................................................................170 Removal of alternator assembly..................................................170 Installation of alternator assembly.............................................171 Water pump assembly.................................................................172 Removal of water pump assembly..................................................172 Installation of water pump assembly.............................................174 Engine cover assembly...............................................................175 Removal of engine cover assembly................................................175 Installation of engine cover assembly...........................................176 Engine cover support assembly.......................................................177 Removal of engine cover support assembly........................................177 Installation of engine cover support assembly...................................178 Engine assembly.....................................................................179 Removal of engine assembly......................................................179 Installation of engine assembly.................................................184 Clutch assembly.....................................................................186 Removal of clutch assembly......................................................186 Installation of clutch assembly.................................................187 Radiator assembly...................................................................188 Removal of radiator assembly....................................................188 Installation of radiator assembly...............................................190 Fan assembly........................................................................191 Removal of fan assembly.........................................................191 Installation of fan assembly....................................................192 Inch brake valve assembly...........................................................193 Removal of inch brake valve assembly............................................193 Installation of inch brake valve assembly.......................................194 Priority valve assembly.............................................................195 Removal of priority valve assembly..............................................195 Installation of priority valve assembly.........................................196 Orbit-roll-valve assembly...........................................................197 Removal of orbit-roll-valve assembly............................................197 Installation of orbit-roll-valve assembly.......................................199 Counterweight assembly..............................................................200 Removal of counterweight assembly...............................................200 Installation of counterweight assembly..........................................201 Control valve assembly (WA65-5 / WA70-5)............................................202 Removal of control valve assembly...............................................202 Installation of control valve assembly..........................................204 Main control valve assembly (WA80-5)................................................205 Removal of main control valve assembly..........................................205 Installation of main control valve assembly.....................................206 Pilot valve assembly (WA80-5).......................................................207 Removal of pilot valve assembly.................................................207 Installation of pilot valve assembly............................................208 Monitor assembly....................................................................209 Removal of monitor assembly.....................................................209 Installation of monitor assembly................................................210 Articulated joint assembly..........................................................211 Removal of articulated joint assembly...........................................211 Installation of articulated joint assembly......................................212 Variable motor assembly.............................................................213 Removal of variable motor assembly..............................................213 Installation of variable motor assembly.........................................215 Rear axle assembly..................................................................216 Removal of rear axle assembly...................................................216 Installation of rear axle assembly..............................................218 Front axle assembly.................................................................219 Removal of front axle assembly..................................................219 Installation of front axle assembly.............................................221 Front axle..........................................................................222 Brake disc group................................................................222 Disassembly.....................................................................222 Assembly........................................................................224 Brake caliper.......................................................................226 Hydraulic principle of operation................................................226 Differential position...........................................................227 Mechanical principle of operation...............................................227 Caliper removal.................................................................227 Disassembly (calliper removed)..................................................228 Disassembly.....................................................................228 Assembly........................................................................230 Caliper reassembly..............................................................232 Replacement of guide protective covers..........................................232 Pad replacement.................................................................233 Brake group - wheel shaft.......................................................234 Disassembly.....................................................................234 Assembly........................................................................237 Rear axle...........................................................................240 Trunnions group and flange......................................................240 Disassembly.....................................................................240 Assembly........................................................................241 Epicyclic reduction gear group..................................................243 Disassembly.....................................................................243 Assembly........................................................................244 Wheel hub.......................................................................245 Disassembly.....................................................................245 Assembly........................................................................247 Wheel shaft.....................................................................249 Disassembly.....................................................................249 Assembly........................................................................250 Differential support group......................................................251 Disassembly.....................................................................251 Assembly........................................................................252 Bevel gear marking test.........................................................255 Differential locking group......................................................256 Disassembly.....................................................................256 Assembly........................................................................257 Differential group (WA80-5).....................................................258 Disassembly.....................................................................258 Assembly........................................................................259 Differential group (WA65-5 / WA70-5)............................................260 Disassembly.....................................................................260 Assembly........................................................................261 Pinion group....................................................................262 Disassembly.....................................................................262 Assembly........................................................................263 Variable displacement pump assembly.................................................266 Removal of variable displacement pump assembly..................................266 Installation of variable displacement pump assembly.............................268 Hydraulic pump assemblies...........................................................269 Removal of the two hydraulic pump assemblies....................................269 Installation of hydraulic pump assembly.........................................270 Quick-attach coupler assembly.......................................................271 Removal of quick-attach coupler assembly........................................271 Installation of quick-attach coupler assembly..................................272 Steering cylinder assembly..........................................................273 Removal of steering cylinder assembly...........................................273 Installation of steering cylinder assembly......................................274 Lift cylinder assembly..............................................................275 Removal of lift cylinder assembly...............................................275 Installation of lift cylinder assembly..........................................276 Dump cylinder assembly..............................................................277 Removal of dump cylinder assembly...............................................277 Installation of dump cylinder assembly..........................................278 Replacing windows in driver’s cab...................................................279 Stuck glass.....................................................................279 Installation....................................................................281 Door and side windows...........................................................282 Door window assembly............................................................282 Side window assembly............................................................282 OTHERS..................................................................................283 Wiring diagram1/5...................................................................293 Wiring diagram 2/5..................................................................295 Wiring diagram 3/5..................................................................297 Wiring diagram 4/5..................................................................299 Wiring diagram 5/5..................................................................301 Wiring diagram, Speed control.......................................................303 Wiring diagram, Immobilizer.........................................................305 Hydraulic circuit diagram 1/4.......................................................285 Hydraulic circuit diagram 2/4.......................................................287 Hydraulic circuit diagram 3/4.......................................................289 Hydraulic circuit diagram 4/4.......................................................291
DESCRIPTION:
KOMATSU WA65-5 WA70-5 WA80-5 WHEEL LOADER SERVICE REPAIR MANUAL (SN:H50051 & UP) KOMATSU WA65-5 WA70-5 WA80-5
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel an accurate understanding of the product and by showing them 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 shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components:
- Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - Testing and adjusting
This section 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.
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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