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KOMATSU WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 WHEEL LOADER SERVICE REPAIR MANUAL(SN:H60051 AND UP) – PDF DOWNLOAD
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- KOMATSU WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 WHEEL LOADER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:VEBM550101
- Serial number:
WA65-6 H60051 AND UP
WA70-6 H60051 AND UP
WA80-6 H60051 AND UP
WA90-6 H00051 AND UP
WA100M-6 H60051 AND UP
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Description
KOMATSU WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 WHEEL LOADER SERVICE REPAIR MANUAL(SN:H60051 AND UP)
KOMATSU WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 WHEEL LOADER SERVICE REPAIR MANUAL(SN:H60051 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 WHEEL LOADER SERVICE REPAIR MANUAL(SN:H60051 AND UP)
- 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
TABLE OF CONTENTS:
KOMATSU WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 WHEEL LOADER SERVICE REPAIR MANUAL(SN:H60051 AND UP)
Contents.............................................................................................................. 3 SAFETY................................................................................................................ 13 Safety notice..................................................................................................... 18 Preparations for work......................................................................................... 19 Tipping up the driver's cab................................................................................... 20 Tipping down the driver's cab................................................................................. 22 Precautions during work....................................................................................... 24 Hydraulic system.............................................................................................. 25 Foreword.......................................................................................................... 26 General....................................................................................................... 26 Structure and function........................................................................................ 26 Testing and adjusting......................................................................................... 26 Disassembly and assembly...................................................................................... 26 Maintenance standard.......................................................................................... 26 How to read the shop manual....................................................................................... 27 Volumes....................................................................................................... 27 Distribution and updating..................................................................................... 27 Filing method................................................................................................. 27 Symbols....................................................................................................... 28 Hoisting instructions............................................................................................. 29 Wire ropes.................................................................................................... 29 GENERAL............................................................................................................... 31 Dimensions, weights and operating data............................................................................ 32 Specifications.................................................................................................... 34 WA65-6 - Specifications....................................................................................... 34 WA70-6 - Specifications....................................................................................... 35 WA80-6 - Specifications....................................................................................... 36 WA90-6 - Specifications....................................................................................... 37 WA100M-6 - Specifications..................................................................................... 38 Weight tables..................................................................................................... 39 WA65-6 - Weight table......................................................................................... 39 WA70-6 - Weight table......................................................................................... 39 WA80-6 - Weight table......................................................................................... 40 WA90-6 - Weight table......................................................................................... 40 WA100M-6 - Weight table....................................................................................... 41 Lubricants and operating mediums.................................................................................. 42 WA65-6, WA70-6 - Lubricants and operating mediums............................................................. 42 WA80-6 - Lubricants and operating mediums..................................................................... 43 WA90-6 - Lubricants and operating mediums..................................................................... 44 WA100M-6 - Lubricants and operating mediums................................................................... 45 Basic procedures of maintenance................................................................................... 46 Oil........................................................................................................... 46 Fuel.......................................................................................................... 46 Coolant....................................................................................................... 47 Grease........................................................................................................ 47 Storing oil and fuel.......................................................................................... 47 Filters....................................................................................................... 48 Biodegradable hydraulic oils and lubricants................................................................... 48 Outline of electric system.................................................................................... 48 Torque list - Screws and nuts..................................................................................... 49 STRUCTURE AND FUNCTION................................................................................................ 53 Powertrain........................................................................................................ 57 Closed circuit.................................................................................................... 58 Hydraulic drive system............................................................................................ 59 WA65-6, WA70-6 - Hydraulic drive system - 20 km/h............................................................. 59 WA80-6 - Hydraulic drive system - 20 km/h and 30 km/h......................................................... 60 WA90-6, WA100M-6 - Hydraulic drive system - 20 km/h and 30 km/h............................................... 61 Variable displacement pump (HST pump)............................................................................. 62 Regulating valve (DA valve)................................................................................... 65 WA65-6, WA70-6, WA80-6 - Charge pump pressure relief valve - 20km/h........................................... 66 WA80-6 ,WA90-6, 100M-6 - Charge pump pressure relief valve - 30km/h........................................... 66 Control cylinder.............................................................................................. 67 4/3 Way valve with direction control solenoids................................................................ 68 Pressure cut-off valve........................................................................................ 69 Safety & charge valve......................................................................................... 70 Towing........................................................................................................ 71 Variable displacement motor (HST motor with HA Control)........................................................... 72 Hydraulic diagram HST motor A6VM80 (or 160) HA1R1............................................................. 74 Directional shuttle valve..................................................................................... 75 Auto inch valve diagram (option).............................................................................. 75 HST motor with DA Control......................................................................................... 76 Hydraulic diagram HST Motor A6VM107(160)DA2................................................................... 77 Drive shaft....................................................................................................... 78 Front axle - Mounting............................................................................................. 79 WA65-6, WA70-6 - Front axle mounting.......................................................................... 79 WA80-6, WA90-6, WA100M-6 - Front axle mounting................................................................ 79 Rear axle - Mounting.............................................................................................. 80 Front axle........................................................................................................ 81 WA65-6, WA70-6 - Front axle with outer disc brake as service brake and parking brake.......................... 81 WA80-6 - Front axle with inner disc brake as service brake and outer disc brake as parking brake.............. 82 WA90-6, WA100M-6 - Front axle with inner disc brake as service brake and outer disc brake as parking brake.... 83 Rear axle with transfer box....................................................................................... 84 WA65-6, WA70-6, WA80-6 - Rear axle with transfer box.......................................................... 84 WA90-6, WA100M-6 - Rear axle with transfer box................................................................ 85 Trasfer box TB172................................................................................................. 86 Limited slip differential......................................................................................... 88 Limited slip differential - Locking value 25%................................................................. 88 Locking differential.............................................................................................. 90 Locking differential - Locking value 100%..................................................................... 90 Wheel hub - Font axle and rear axle............................................................................... 92 Service and parking brake - Front axle............................................................................ 94 WA65-6, WA70-6 - Service and parking brake.................................................................... 94 WA80-6, WA90-6, WA100M-6 - Service brake...................................................................... 96 WA80-6, WA90-6, WA100M-6 - Parking brake...................................................................... 97 Service and parking brake circuit................................................................................. 98 WA65-6, WA70-6 - Service and parking brake circuit............................................................ 98 WA80-6 - Service and parking brake circuit.................................................................... 99 WA90-6, WA100M-6 - Service and parking brake circuit..........................................................100 Service brake assembly............................................................................................101 WA65-6, WA70-6 - Service brake assembly.......................................................................101 WA80-6 - Service brake assembly...............................................................................102 WA90-6, WA100M-6 - Service brake assembly.....................................................................103 Main-brake valve..................................................................................................104 WA65-6, WA70-6 - Main-brake valve.............................................................................104 WA80, WA90-6, WA100M-6 - Main-brake valve.....................................................................105 Steering articulation joint.......................................................................................106 Steering system...................................................................................................108 WA65-6, WA70-6 - Hydraulic circuit diagram of steering system.................................................108 WA80-6 - Hydraulic circuit diagram of steering system.........................................................110 WA90-6, WA100M-6 - Hydraulic circuit diagram of steering system...............................................112 Priority valve................................................................................................114 Orbit-roll-valve..............................................................................................115 Steering relief valve.........................................................................................116 Work equipment hydraulic..........................................................................................118 WA65-6, WA70-6 - Travel, steering and work hydraulics.........................................................118 WA80-6 - Travel, steering and work hydraulics.................................................................120 WA90-6, WA100M-6 - Travel, steering and work hydraulics.......................................................122 PPC-Valve WA90-6, WA100M-6........................................................................................124 Operation of PPC-valve........................................................................................125 Servo pressure regulating valve...............................................................................126 Emergency Lowering System.....................................................................................126 Main control valve................................................................................................127 Main control valve WA65-6, WA70-6, WA80-6.....................................................................127 Main control valve WA90-6, WA100M-6...........................................................................128 Lift cylinder.....................................................................................................129 WA65-6, WA70-6 - Lift cylinder................................................................................129 WA80-6 - Lift cylinder........................................................................................130 WA90-6 - Lift cylinder........................................................................................131 WA100M-6 - Lift cylinder......................................................................................132 Dump cylinder.....................................................................................................133 WA65-6, WA70-6 - Dump cylinder................................................................................133 WA80-6 - Dump cylinder........................................................................................134 WA90-6 - Dump cylinder........................................................................................135 WA100M-6 - Dump cylinder......................................................................................136 Steering cylinder.................................................................................................137 WA65-6, WA70-6 - Steering cylinder............................................................................137 WA80-6 - Steering cylinder....................................................................................138 WA90-6, WA100M-6 - Steering cylinder..........................................................................139 Loader Linkage with quick-coupler.................................................................................140 WA65-6, WA70-6 - Loader Linkage with quick-coupler............................................................140 WA80-6, WA90-6, WA100M-6 - Loader Linkage with quick-coupler..................................................141 Quick-coupler.....................................................................................................142 WA65-6, WA70-6 - Quick-coupler................................................................................142 WA80-6 - Quick-coupler........................................................................................143 WA90-6, WA100M-6 - Quick-coupler..............................................................................144 Monitor display...................................................................................................146 WA65-6, WA70-6, WA80-6 - Monitor display......................................................................146 WA90-6, WA100M-6 - Monitor display............................................................................148 Special monitor functions.....................................................................................150 Monitor panel adjustment......................................................................................151 Adjustment switches.......................................................................................151 Adjustment table..........................................................................................152 WA65-6, WA70-6 Tire table.................................................................................154 WA80-6 Tire table.........................................................................................155 WA90-6 Tire table.........................................................................................156 WA100M-6 Tire table.......................................................................................157 Reading error codes WA90-6, WA100M-6..........................................................................158 Trouble Codes and Cummins Fault Codes.........................................................................159 Sensors...........................................................................................................167 Engine oil pressure sensor....................................................................................167 Fuel level sensor.............................................................................................168 Engine coolant temperature sensor.............................................................................169 Brake oil reservoir sensor....................................................................................170 Pre-heater........................................................................................................172 WA65-6, WA70-6, WA80-6 - Glow plugs...........................................................................172 WA90-6, WA100M-6 - Ribbon heater..............................................................................173 Engine stop / start / preheating circuit..........................................................................174 WA65-6, WA70-6, WA80-6........................................................................................174 WA90-6, WA100M-6..............................................................................................176 Electrical fuses and relays.......................................................................................178 Fuses.........................................................................................................178 Relays........................................................................................................179 Engine room...................................................................................................180 Diagrams..........................................................................................................181 Wiring diagrams...............................................................................................181 Hydraulic circuit diagram.....................................................................................181 Air conditioner (option)..........................................................................................182 Introduction..................................................................................................182 Function......................................................................................................183 The coolant circuit.......................................................................................183 The condenser.............................................................................................185 The vaporizer.............................................................................................186 The filter dryer..........................................................................................187 Installation of air conditioner...............................................................................188 Safety when handling coolants.................................................................................189 Operating the air conditioner.................................................................................191 Maintenance of the air conditioner............................................................................192 Regular maintenance.......................................................................................193 Instructions for filling......................................................................................195 Exchange of magnetic clutch...................................................................................198 Exchange of compressor........................................................................................199 Troubleshooting...............................................................................................201 TESTING AND ADJUSTING.................................................................................................203 Standard value table for engine...................................................................................206 WA65-6, WA70-6, WA80-6 - Standard value table for engine......................................................206 WA90-6, WA100M-6 - Standard value table for engine............................................................207 Standard value table for chassis..................................................................................208 WA65-6 - Standard value table for chassis.....................................................................208 WA70-6 - Standard value table for chassis.....................................................................210 WA80-6 - Standard value table for chassis.....................................................................212 WA90-6 - Standard value table for chassis.....................................................................214 WA100M-6 - Standard value table for chassis...................................................................216 Standard value table for electrical parts.........................................................................218 Test certificate..................................................................................................219 WA65-6 - Test certficate......................................................................................219 WA70-6 - Test certificate.....................................................................................220 WA80-6 - Test certificate.....................................................................................221 WA90-6 - Test certificate.....................................................................................222 WA100M-6 - Test certificate...................................................................................223 Valve lash clearance..............................................................................................224 WA65-6, WA70-6, WA80-6 - Valve lash clearance.................................................................224 WA90-6, WA100M-6 - Valve lash clearance.......................................................................226 Engine compression test...........................................................................................228 WA65-6, WA70-6, WA80-6 - Engine compression test..............................................................228 WA90-6, WA100M-6 - Engine compression test....................................................................229 Testing blow-by pressure......................................................................................232 Fuel system.......................................................................................................233 Handling fuel system parts....................................................................................233 Releasing residual pressure in fuel system....................................................................233 WA65-6, WA70-6, WA80-6 - Adjusting fuel injection pressure (cracking pressure)................................234 WA65-6, WA70-6, WA80-6 - Shim data for adjusting injection pressure...........................................235 WA65-5, WA70-6, WA80-6 - Testing and adjusting fuel injection timing..........................................236 WA90-6, WA100M-6 - Testing fuel pressure......................................................................240 Reduced cylinder mode operation...........................................................................241 No-injection cranking.....................................................................................241 WA90-6, WA100M-6 - Testing leakage from pressure limiter and return rate from injector........................242 WA90-6, WA100M-6 - Bleeding air from fuel circuit.............................................................245 WA90-6, WA100M-6 - Testing fuel system for leakage............................................................247 V-belt tension....................................................................................................248 Engine RPM........................................................................................................249 Testing travel speed..............................................................................................250 Engine stall torque RPM...........................................................................................251 Engine stall torque RPM, test with the hydrostatic drive......................................................252 Engine stall torque RPM, test with hydrostatic drive and working hydraulics...................................253 Feed pump (and servo oil pressure)............................................................................254 WA90-6 and WA100M-6.......................................................................................254 Hydraulic pressure cut-off........................................................................................255 Working hydraulic pressure........................................................................................257 Steering oil pressure.............................................................................................258 Testing.......................................................................................................258 Adjusting.....................................................................................................259 Operating time for steering wheel.................................................................................260 Operating force of steering wheel.................................................................................261 Disc brake (foot brake)...........................................................................................262 WA80-6, WA90-6, WA100M-6 - Disc brake (foot brake)............................................................262 Brake.............................................................................................................263 WA65-6, WA70-6 - Brake........................................................................................263 Main brake valve - basic adjustment...............................................................................264 WA65-6, WA70-6................................................................................................264 WA80-6, WA90-6, WA100M-6......................................................................................264 Brake efficiency..................................................................................................265 Measuring the stopping distance...............................................................................265 Parking brake efficiency..........................................................................................266 Bleeding/ filling up the brake circuit............................................................................267 WA65-6, WA70-6 - Bleeding/ filling up the brake circuit.......................................................267 Ventilation / filling up the brake circuit........................................................................269 WA80-6, WA90-6, WA100M-6 - Ventilation / filling up the brake circuit.........................................269 Cabin - adjustment................................................................................................270 Proportional amplifier............................................................................................271 DISASSEMBLY AND ASSEMBLY..............................................................................................273 Comments..........................................................................................................277 Starter assembly..................................................................................................278 Removal of starter assembly...................................................................................278 Installation of starter assembly..............................................................................279 Alternator assembly...............................................................................................280 Removal of alternator assembly................................................................................280 Installation of alternator assembly...........................................................................281 Radiator assembly.................................................................................................282 Removal of radiator assembly..................................................................................282 Installation of radiator assembly.............................................................................286 Fan assembly......................................................................................................287 Removal of fan assembly.......................................................................................287 Installation of fan assembly..................................................................................288 Water pump assembly...............................................................................................289 Removal of water pump assembly................................................................................289 Installation of water pump assembly...........................................................................291 Fuel tank assembly................................................................................................292 Removal and installation of fuel tank assembly................................................................292 Installation..............................................................................................292 Engine cover assembly.............................................................................................293 Removal of engine cover assembly..............................................................................293 Installation of engine cover assembly.........................................................................294 Engine cover support assembly.....................................................................................295 Removal of engine cover support assembly......................................................................295 Installation of engine cover support assembly.................................................................296 Engine assembly...................................................................................................297 Removal of engine assembly....................................................................................297 Installation of engine assembly...............................................................................303 Clutch assembly...................................................................................................305 Removal of clutch assembly....................................................................................305 Installation of clutch assembly...............................................................................306 Main brake valve assembly.........................................................................................307 Removal of main brake valve assembly..........................................................................307 Installation of main brake valve assembly.....................................................................308 Priority valve assembly...........................................................................................309 Removal of priority valve assembly............................................................................309 Installation of priority valve assembly.......................................................................310 Orbit-roll-valve assembly.........................................................................................311 Removal of orbit-roll-valve assembly..........................................................................311 Installation of orbit-roll-valve assembly.....................................................................313 Counterweight assembly............................................................................................314 Removal of counterweight assembly.............................................................................314 Installation of counterweight assembly........................................................................316 Main control valve assembly - WA65-6, WA70-6, WA80-6..............................................................317 Removal of control valve assembly.............................................................................317 Installation of main control valve assembly...................................................................319 Main control valve assembly - WA90-6, WA100M-6....................................................................320 Removal of main control valve assembly........................................................................320 Installation of main control valve assembly...................................................................321 Pilot valve assambly WA90-6, WA100M-6.............................................................................322 Removal of pilot valve assembly...............................................................................322 Installation of pilot valve assembly..........................................................................324 Monitor assembly..................................................................................................325 Removal of monitor assembly...................................................................................325 Installation of monitor assembly..............................................................................326 Articulated joint assembly........................................................................................327 Removal of articulated joint assembly.........................................................................327 Installation of articulated joint assembly....................................................................328 Variable motor assembly...........................................................................................329 Removal of variable motor assembly............................................................................329 Installation of variable motor assembly.......................................................................331 Rear axle assembly................................................................................................332 Removal of rear axle assembly.................................................................................332 Installation of rear axle assembly............................................................................334 Front axle assembly...............................................................................................335 Removal of front axle assembly................................................................................335 Installation of front axle assembly...........................................................................337 Front axle........................................................................................................338 Brake disc group..............................................................................................338 Disassembly...................................................................................................338 Assembly..................................................................................................340 Brake caliper.....................................................................................................342 Hydraulic principle of operation..............................................................................342 Differential position.........................................................................................343 Mechanical principle of operation.............................................................................343 Caliper removal...............................................................................................343 Disassembly (calliper removed)............................................................................344 Disassembly...............................................................................................344 Assembly..................................................................................................346 Caliper reassembly............................................................................................348 Replacement of guide protective covers........................................................................348 Pad replacement...............................................................................................349 Brake group - wheel shaft.........................................................................................350 Disassembly...................................................................................................350 Assembly......................................................................................................353 Rear axle.........................................................................................................356 Trunnions group and flange....................................................................................356 Disassembly...................................................................................................356 Assembly......................................................................................................357 Epicyclic reduction gear group....................................................................................359 Disassembly...................................................................................................359 Assembly......................................................................................................360 Wheel hub.........................................................................................................361 Disassembly...................................................................................................361 Assembly......................................................................................................363 Wheel shaft - WA65-6, WA70-6......................................................................................365 Disassembly...................................................................................................365 Assembly......................................................................................................366 Wheel shaft - WA80-6, WA90-6, WA100M-6............................................................................367 Disassembly...................................................................................................367 Assembly......................................................................................................368 Differential support group........................................................................................369 Disassembly...................................................................................................369 Assembly......................................................................................................370 Bevel gear marking test.......................................................................................374 Differential locking group........................................................................................375 Disassembly...................................................................................................375 Assembly......................................................................................................376 Differential group (100% Differential Lock).......................................................................377 Disassembly...................................................................................................377 Assembly......................................................................................................378 Differential group (LSD 25%)......................................................................................379 Disassembly...................................................................................................379 Assembly......................................................................................................380 Pinion group......................................................................................................381 Disassembly...................................................................................................381 Assembly......................................................................................................382 Transmission box..................................................................................................385 Disassembly...................................................................................................385 Assembly......................................................................................................390 Variable displacement pump assembly...............................................................................395 Removal of variable displacement pump assembly................................................................395 Installation of variable displacement pump assembly...........................................................397 Hydraulic pump assemblies.........................................................................................398 Removal of the two hydraulic pump assemblies..................................................................398 Installation of hydraulic pump assembly.......................................................................399 Turbocharger assembly - WA80-6, WA90-6, WA100M-6..................................................................400 Removal of the turbocharger...................................................................................400 Installation of the turbocharger..............................................................................400 Quick coupler assembly............................................................................................401 Removal of quick coupler assembly.............................................................................401 Installation of quick coupler assembly........................................................................402 Steering cylinder assembly........................................................................................403 Removal of steering cylinder assembly.........................................................................403 Installation of steering cylinder assembly....................................................................404 Lift cylinder assembly............................................................................................405 Removal of lift cylinder assembly.............................................................................405 Installation of lift cylinder assembly........................................................................406 Dump cylinder assembly............................................................................................407 Removal of dump cylinder assembly.............................................................................407 Installation of dump cylinder assembly........................................................................408 Replacing windows in driver’s cab.................................................................................409 Stuck glass...................................................................................................409 Installation..................................................................................................411 Door and side windows.........................................................................................412 Door window assembly......................................................................................412 Side window assembly......................................................................................412 others................................................................................................................413 Hydraulic circuit diagram - WA65-6, WA70-6........................................................................415 Hydraulic circuit diagram - WA80-6................................................................................416 Hydraulic circuit diagram - WA90-6, WA100M-6......................................................................417 Wiring diagram 2/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6.....................................................419 Wiring diagram 8/9 - WA90-6, WA100M-6.............................................................................425 Wiring diagram 3/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6.....................................................420 Wiring diagram 4/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6.....................................................421 Wiring diagram 5/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6.....................................................422 Wiring diagram 6/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6.....................................................423 Wiring diagram 7/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6.....................................................424 Wiring diagram 9/9 - WA65-6, WA70-6, WA80-6-6.....................................................................426 Wiring diagram 1/9 - WA90-6, WA100M-6.............................................................................418
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
