Komatsu WA80M-7,WA100M-7 Wheel Loader Shop Manual VENBM03000 PDF
$31.95
Komatsu WA80M-7,WA100M-7 Wheel Loader Shop Manual VENBM03000 – PDF DOWNLOAD
- Model: Serial number:WA80M-7 H62051 AND UPWA100M-7 H62051 AND UP
Description
Komatsu WA80M-7,WA100M-7 Wheel Loader Shop Manual VENBM03000 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WA80M-7,WA100M-7 Wheel Loader Shop Manual VENBM03000 – PDF DOWNLOAD
Language : English
Pages : 626
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu WA80M-7,WA100M-7 Wheel Loader Shop Manual VENBM03000 – PDF DOWNLOAD
- Model: Serial number:WA80M-7 H62051 AND UPWA100M-7 H62051 AND UP
Contents 3
SAFETY 13
Safety notice . 14
Preparations for work . 15
Tipping up the driver’s cab . 16
Tipping down the driver’s cab . 18
Precautions during work . 20
Hydraulic system 21
Foreword 22
General . 22
Structure and function 22
Testing and adjusting . 22
Disassembly and assembly 22
Maintenance standard 22
How to read the shop manual . 23
Volumes . 23
Distribution and updating . 23
Filing method . 23
Symbols . 24
Hoisting instructions . 25
Wire ropes 25
GENERAL . 27
Dimensions, weights and operating data 28
Specifications 30
WA80M-7 – Specifications 30
WA100M-7 – Specifications . 31
Weight tables . 32
WA80M-7 – Weight table 32
WA100M-7 – Weight table . 32
Lubricants and operating mediums 33
WA80M-7 – Lubricants and operating mediums 33
WA100M-7 – Lubricants and operating mediums . 34
Basic procedures of maintenance . 35
Oil . 35
Fuel 35
Coolant . 36
Grease 36
Storing oil and fuel 36
Filters . 37
Biodegradable hydraulic oils and lubricants . 37
Outline of electric system 37
Torque list – Screws and nuts . 38
STRUCTURE AND FUNCTION 41
Powertrain 45
Closed circuit 46
Hydraulic drive system 47
WA80M-7 – Hydraulic drive system – 20 km/h and 30 km/h 47
WA100M-7 – Hydraulic drive system – 20 km/h and 30 km/h . 48
Variable displacement pump (HST pump) . 49
Regulating valve (DA valve) . 52
WA80M-7 – Charge pump pressure relief valve – 20km/h 53
WA80M-7, WA100M-7 – Charge pump pressure relief valve – 30km/h 53
Control cylinder 54
4/3 Way valve with direction control solenoids 55
Pressure cut-off valve 56
Safety & charge valve . 57
Towing 58
Variable displacement motor (HST motor with HA Control) . 59
Hydraulic diagram HST motor A6VM85 (or 150) HA1R1 . 61
Directional shuttle valve . 62
Auto inch valve diagram (option) 62
HST motor with DA Control . 63
Hydraulic diagram HST Motor A6VM107(160)DA2 . 64
Drive shaft . 65
Front axle – Mounting . 66
WA80M-7, WA100M-7 – Front axle mounting . 66
Rear axle – Mounting 67
Front axle 68
WA80M-7 – Front axle with inner disc brake as service brake and outer disc brake as parking brake . 68
WA100M-7 – Front axle with inner disc brake as service brake and outer disc brake as parking brake 69
Rear axle with transfer box . 70
WA80M-7 – Rear axle with transfer box . 70
WA100M-7 – Rear axle with transfer box 71
Transfer box TB172 72
Limited slip differential . 74
Limited slip differential – Locking value 25% . 74
Locking differential 76
Locking differential – Locking value 100% . 76
Wheel hub – Font axle and rear axle . 78
Service and parking brake – Front axle 80
WA80M-7, WA100M-7 – Service brake . 80
WA80M-7, WA100M-7 – Parking brake . 81
Service and parking brake circuit . 82
WA80M-7 – Service and parking brake circuit . 82
WA100M-7 – Service and parking brake circuit 83
Service brake assembly 84
WA80M-7, WA100M-7 – Service brake assembly 84
Main-brake valve 85
WA80M-7, WA100M-7 – Main-brake valve 85
Steering articulation joint . 86
Steering system . 88
WA80M-7 – Hydraulic circuit diagram of steering system 88
WA100M-7 – Hydraulic circuit diagram of steering system . 90
Priority valve 92
Orbit-roll-valve 93
Steering relief valve . 94
Work equipment hydraulic 96
WA80M-7 – Travel, steering and work hydraulics 96
WA100M-7 – Travel, steering and work hydraulics . 98
PPC-Valve WA100M-7 100
Operation of PPC-valve 101
Servo pressure regulating valve .102
Emergency Lowering System .102
Main control valve 103
Main control valve WA80M-7 103
Main control valve WA100M-7 .104
Lift cylinder .105
WA80M-7 – Lift cylinder .105
WA100M-7 – Lift cylinder 106
Dump cylinder .107
WA80M-7 – Dump cylinder .107
WA100M-7 – Dump cylinder 108
Steering cylinder .109
WA80M-7 – Steering cylinder .109
WA100M-7 – Steering cylinder 110
Loader Linkage with quick-coupler .111
WA80M-7, WA100M-7 – Loader Linkage with quick-coupler .111
Quick-coupler .112
WA80M-7 – Quick-coupler .112
WA100M-7 – Quick-coupler 113
Monitor display .114
WA80M-7, WA100M-7 – Monitor display .114
Special monitor functions .116
Monitor Service Menu 118
Reading Fault codes .127
Fault Codes List 128
Sensors .130
Engine oil pressure switch 131
Fuel level sensor .132
Engine coolant temperature sensor .133
Brake oil reservoir sensor 134
Ambient pressure sensor .134
Charge (boost) pressure and temperature sensor 135
NE (crankshaft) speed sensor 135
Bkup (camshaft) speed sensor 136
Common rail pressure sensor .136
Crankcase pressure sensor .137
Mass air flow and temperature sensor 137
Variable Flow Turbocharger motor (with built-in position sensor) 138
EGR valve (with built-in position sensor) .139
Pre-heater 141
WA80M-7, WA100M-7 – Ribbon heater .141
Electrical fuses and relays .142
Fuses .142
Slow-blow fuses .144
Relays 145
Diagrams 146
Wiring diagrams .146
Hydraulic circuit diagram .146
Air conditioner (option) 147
Introduction 147
Function 148
The coolant circuit .148
The condenser .150
The vaporizer .151
The filter dryer 152
Installation of air conditioner .153
Safety when handling coolants .154
Operating the air conditioner .156
Maintenance of the air conditioner 157
Regular maintenance .158
Instructions for filling 160
Exchange of magnetic clutch .163
Exchange of compressor 164
Troubleshooting .166
TESTING AND ADJUSTING .169
Standard value table for engine .172
WA80M-7 – Standard value table for engine .172
WA100M-7 – Standard value table for engine 173
Standard value table for chassis 174
WA80M-7 – Standard value table for chassis 174
WA100M-7 – Standard value table for chassis .176
Standard value table for electrical parts .178
Test certificate 179
WA80M-7 – Test certificate 179
WA100M-7 – Test certificate .180
Valve clearance .181
WA80M-7, WA100M-7 – Valve clearance .181
Engine compression test .183
WA80M-7, WA100M-7 – Engine compression test .183
Testing blowby pressure .185
Fuel system .186
Handling fuel system parts 186
Handling of intake system parts .186
Releasing residual pressure in fuel system 187
WA80M-7, WA100M-7 – Testing fuel pressure .188
Reduced cylinder mode operation .190
WA80M-7, WA100M- 7 Testing leakage from pressure limiter and return rate from injector 191
WA80M-7, WA100M-7 – Bleeding air from fuel circuit 194
WA80M-7, WA100M-7 – Testing fuel system for leakage .196
V-belt tension 198
Engine RPM 199
Testing travel speed 200
Engine stall torque RPM .201
Engine stall torque RPM, test with the hydrostatic drive 202
Engine stall torque RPM, test with hydrostatic drive and working hydraulics .203
Feed pump (and servo oil pressure) 204
WA80M-7 and WA100M-7 204
Hydraulic pressure cut-off 205
Working hydraulic pressure 207
Steering oil pressure .208
Testing .208
Adjusting .209
Operating time for steering wheel .210
Operating force of steering wheel .211
Disc brake (foot brake) .212
WA80M-7, WA100M-7 – Disc brake (foot brake) .212
Main brake valve – basic adjustment .213
Brake efficiency 214
Measuring the stopping distance .214
Parking brake efficiency 215
Ventilation / filling up the brake circuit 216
WA80M-7, WA100M-7 – Ventilation / filling up the brake circuit 216
Cabin – adjustment 218
Proportional amplifier 219
DISASSEMBLY AND ASSEMBLY 221
Comments 225
Starter assembly 226
Removal of starter assembly .226
Installation of starter assembly 227
Alternator assembly .228
Removal of alternator assembly 228
Installation of alternator assembly .229
Counterweight assembly 230
Removal of counterweight assembly .230
Installation of counterweight assembly 231
Engine cover assembly .232
Removal of engine cover assembly 232
Installation of engine cover assembly .233
Radiator and hydraulic tank assembly 234
Removal of radiator and hydraulic tank assembly .234
Installation of radiator and hydraulic tank assembly 239
Fan assembly 240
Removal of fan assembly .240
Installation of fan assembly 241
Water pump assembly .242
Removal of water pump assembly 242
Installation of water pump assembly .243
Engine assembly .244
Removal of engine assembly 244
Installation of engine assembly .251
Clutch assembly .253
Removal of clutch assembly 253
Installation of clutch assembly .254
Fuel tank assembly 255
Removal and installation of fuel tank assembly 255
Installation 255
Main brake valve assembly .256
Removal of main brake valve assembly 256
Installation of main brake valve assembly .257
Priority valve assembly .258
Removal of priority valve assembly 258
Installation of priority valve assembly .259
Orbit-roll-valve assembly .260
Removal of orbit-roll-valve assembly 260
Installation of orbit-roll-valve assembly .262
Main control valve assembly WA80M-7 .263
Removal of pilot valve assembly .263
Installation of main control valve assembly .265
Main control valve assembly – WA100M-7 266
Removal of main control valve assembly 266
Installation of main control valve assembly .267
Pilot valve assembly WA100M-7 .268
Removal of pilot valve assembly .268
Installation of pilot valve assembly 270
Monitor assembly 271
Removal of monitor assembly .271
Installation of monitor assembly 272
Articulated joint assembly 273
Removal of articulated joint assembly .273
Installation of articulated joint assembly 274
Variable motor assembly .275
Removal of variable motor assembly 275
Installation of variable motor assembly .277
Rear axle assembly 278
Removal of rear axle assembly .278
Installation of rear axle assembly 280
Front axle assembly .281
Removal of front axle assembly 281
Installation of front axle assembly .283
Front axle 284
Brake disc group 284
Disassembly .284
Assembly 286
Brake calliper 288
Hydraulic principle of operation 288
Differential position .289
Mechanical principle of operation .289
Calliper removal 289
Disassembly (calliper removed) 290
Disassembly .290
Assembly 292
Calliper reassembly .294
Replacement of guide protective covers 294
Pad replacement .295
Brake group – wheel shaft .296
Disassembly .296
Assembly 299
Rear axle .302
Trunnions group and flange 302
Disassembly .302
Assembly 303
Epicyclic reduction gear group 305
Disassembly .305
Assembly 306
Wheel hub .307
Disassembly .307
Assembly 309
Wheel shaft – WA80M-7, WA100M-7 .311
Disassembly .311
Assembly 312
Differential support group 313
Disassembly .313
Assembly 314
Bevel gear marking test .318
Differential locking group 319
Disassembly .319
Assembly 320
Differential group (100% Differential Lock) .321
Disassembly .321
Assembly 322
Differential group (LSD 25%) 323
Disassembly .323
Assembly 324
Pinion group 325
Disassembly .325
Assembly 326
Transmission box 329
Disassembly .329
Assembly 334
Variable displacement pump assembly .339
Removal of variable displacement pump assembly 339
Installation of variable displacement pump assembly .341
Hydraulic pump assemblies .342
Removal of the two hydraulic pump assemblies 342
Installation of hydraulic pump assembly .343
Variable geometry turbocharger assembly – WA80M-7, WA100M-7 .344
Removal of the turbocharger .344
Installation of the turbocharger 344
Quick coupler assembly 345
Removal of quick coupler assembly .345
Installation of quick coupler assembly 346
Steering cylinder assembly 347
Removal of steering cylinder assembly .347
Installation of steering cylinder assembly 348
Lift cylinder assembly 349
Removal of lift cylinder assembly .349
Installation of lift cylinder assembly 350
Dump cylinder assembly 351
Removal of dump cylinder assembly .351
Installation of dump cylinder assembly 352
Replacing windows in driver’s cab .353
Stuck glass .353
Installation 355
Door and side windows .356
Door window assembly 356
Side window assembly 356
others 357
Hydraulic circuit diagram – WA80M-7 .359
Hydraulic circuit diagram – WA100M-7 360
Wiring diagram 2/8 – WA80M-7, WA100M-7 362
Wiring diagram 8/8 – WA80M-7, WA100M-7 368
Wiring diagram 3/8 – WA80M-7, WA100M-7 363
Wiring diagram 4/8 – WA80M-7, WA100M-7 364
Wiring diagram 5/8 – WA80M-7, WA100M-7 365
Wiring diagram 6/8 – WA80M-7, WA100M-7 366
Wiring diagram 7/8 – WA80M-7, WA100M-7 367
Wiring diagram 1/8 – WA80M-7, WA100M-7 361
Shop Manual Engine 369
00 Index and foreword 369
Index 370
Foreword, safety and general information .373
Important safety notice 373
How to read the shop manual 380
Explanation of terms for maintenance standard 382
Handling equipment of fuel system devices 384
Handling of intake system parts 385
Handling of hydraulic equipment 386
Method of disconnecting and connecting of push-pull type coupler .388
Handling of electrical equipment .391
How to read electric wire code .399
Precautions when performing operation 402
Standard tightening torque table .407
List of abbreviation .413
Conversion table .418
01 Specification .423
Table of contents 424
General information 425
Exhaust gas regulation .425
Specifications .428
Applicable machines 428
Specifications .429
General view .431
Weight table .440
Engine performance curve .441
10 Structure and function 443
Table of contents 444
Components layout 445
Components layout drawing 445
Intake and exhaust system parts 447
Intake and exhaust system layout drawing .447
Intake and exhaust system circuit diagram 449
Air cleaner 451
VFT 452
EGR system piping drawing 456
EGR system circuit diagram .458
EGR valve 459
EGR cooler .461
KCCV layout drawing 463
KCCV ventilator 465
KDOC muffler .469
Engine main body parts .471
General structure 471
Cylinder head 475
Cylinder block .477
Main moving parts 479
Timing gear 482
Front cover 484
Valve system .485
Flywheel and flywheel housing 487
Lubrication system .488
Lubrication system chart .488
Oil pump .490
Oil filter .492
Oil cooler .494
Oil pan 495
Fuel system 496
Fuel system parts layout drawing .496
Fuel system circuit diagram 498
Prefilter 499
Main filter 500
Supply pump 501
Common rail 502
Injector .503
Cooling system .507
Cooling system parts layout drawing 507
Cooling system chart .508
Drive pulley .509
Water pump .511
Thermostat and jiggle valve 512
Electrical equipment .516
Alternator .516
Starting motor .521
Intake air heater 525
Engine harness .526
Engine controller 528
Sensor .534
20 Standard value tables .543
Table of contents 544
Standard service value table .545
Standard value table for engine 545
Running-in standard and performance test standard 547
50 Disassembly and assembly 551
Table of contents 552
Related information on disassembly and assembly 553
How to read this manual 553
Coating materials list .555
Special tools list .559
Sketches of special tools 560
Disassembly and assembly .561
General disassembly of engine 561
General assembly of engine .576
Removal and installation procedure of supply pump unit alone .599
Engine front oil seal replacement procedure 602
Engine rear oil seal replacement procedure .603
60 Maintenance standard 605
Table of contents 606
Intake and exhaust system parts 607
VFT 607
Engine main body parts .608
Cylinder head 608
Cylinder block .610
Crankshaft .612
Piston .613
Connecting rod .614
Timing gear 615
Camshaft .616
Valve system .617
Valve and valve guide 618
Rocker arm shaft, push rod, and tappet .619
Flywheel and flywheel housing 620
Lubrication system .622
Oil pump .622
Cooling system .624
Water pump .624
DESCRIPTION:
Komatsu WA80M-7,WA100M-7 Wheel Loader Shop Manual VENBM03000 – PDF DOWNLOAD
- Model: Serial number:WA80M-7 H62051 AND UPWA100M-7 H62051 AND UP
G.B 27/12/24
