Komatsu WA65-6,WA70-6,WA80-6,WA90-6,WA100M-6 Wheel Loader Shop Manual PDF

Description

Komatsu WA65-6,WA70-6,WA80-6,WA90-6,WA100M-6 Wheel Loader Shop Manual VEBM550101 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA65-6,WA70-6,WA80-6,WA90-6,WA100M-6 Wheel Loader Shop Manual VEBM550101 – PDF DOWNLOAD

Language : English
Pages : 426
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA65-6,WA70-6,WA80-6,WA90-6,WA100M-6 Wheel Loader Shop Manual VEBM550101 – PDF DOWNLOAD

• Model:               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

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

DESCRIPTION:

Komatsu WA65-6,WA70-6,WA80-6,WA90-6,WA100M-6 Wheel Loader Shop Manual VEBM550101 – PDF DOWNLOAD

• Model:               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

G.B 25/12/24