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KOMATSU WA90-5 WA100M-5 WHEEL LOADER SHOP MANUAL VEBM270100 – PDF DOWNLOAD
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KOMATSU WA90-5 WA100M-5 WHEEL LOADER SHOP MANUAL VEBM270100 – PDF DOWNLOAD
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Description
KOMATSU WA90-5 WA100M-5 WHEEL LOADER SHOP MANUAL VEBM270100 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA90-5 WA100M-5 WHEEL LOADER SHOP MANUAL VEBM270100 – PDF DOWNLOAD
Language : English
Pages : 301
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA90-5 WA100M-5 WHEEL LOADER SHOP MANUAL VEBM270100 – PDF DOWNLOAD
SAFETY.................................................................................. 3 Safety notice....................................................................... 5 Preparations for work........................................................... 6 Tipping up the driver's cab..................................................... 6 Tipping down the driver's cab................................................... 8 Tipping up the driver's cab (option with electric actuator)..................... 10 Tipping down the driver's cab (option with electric actuator)................... 12 Precautions during work......................................................... 13 Hydraulic system................................................................ 14 Foreword............................................................................ 15 How to read the shop manual......................................................... 16 Volumes......................................................................... 16 Distribution and updating....................................................... 16 Filing method................................................................... 16 Symbols......................................................................... 17 Hoisting instructions............................................................... 18 Wire ropes...................................................................... 18 GENERAL................................................................................. 21 Dimensions, weights and operating data WA90-5....................................... 23 Specifications WA90-5............................................................... 24 Weight table WA90-5................................................................. 25 Dimensions, weights and operating data WA100M-5..................................... 26 Specifications WA100M-5............................................................. 27 Weight table WA100M-5............................................................... 28 Lubricants and operating mediums: WA90-5............................................ 30 Lubricants and operating mediums: WA100M-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 Steering system..................................................................... 68 Hydraulic circuit diagram of steering system.................................... 68 Powertrain.......................................................................... 39 Closed circuit...................................................................... 40 Hydraulic drive system.............................................................. 41 20km/h and 30km/h............................................................... 41 Variable displacement pump.......................................................... 42 Regulating valve................................................................ 45 Charge pressure limiting valve.................................................. 45 Control cylinder................................................................ 46 4/3 Way valve with direction control solenoids.................................. 46 Pressure cut-off valve.......................................................... 47 Safety-/charge valve............................................................ 47 Towing.......................................................................... 48 Variable displacement motor......................................................... 49 Drive shaft......................................................................... 51 Axle mounting - front axle.......................................................... 52 Axle mounting - rear axle........................................................... 52 Front axle.......................................................................... 53 With inner disc brake as service brake and outer disc brake as parking brake.... 53 Rear axle with transfer box......................................................... 54 Transfer box TB172.................................................................. 55 Limited slip differential........................................................... 56 locking value 25%............................................................... 56 Locking differential................................................................ 58 locking value 100%.............................................................. 58 Wheel hub, front and rear axle...................................................... 60 Service brake, front axle........................................................... 61 Parking brake, front axle........................................................... 62 Service and parking brake circuit................................................... 63 Service brake assembly.............................................................. 64 Main-brake Valve.................................................................... 65 Steering articulation joint......................................................... 66 Priority valve.................................................................. 70 Orbit-roll-valve................................................................ 71 Steering relief valve........................................................... 72 Work equipment hydraulic............................................................ 74 Travel, steering and work hydraulics............................................ 74 PPC-Valve........................................................................... 76 Operation of PPC-valve.......................................................... 77 Servo pressure regulating valve................................................. 78 Emergency Lowering System....................................................... 78 Main control valve.................................................................. 80 WA90-5: Lift cylinder............................................................... 82 WA100M-5: Lift cylinder............................................................. 83 WA90-5: Dump cylinder............................................................... 84 WA100M-5: Dump cylinder............................................................. 85 Steering cylinder................................................................... 86 Loader Linkage with quick-coupler................................................... 88 Quick-coupler....................................................................... 89 Monitor display..................................................................... 90 Sensors............................................................................. 91 Engine oil pressure sensor...................................................... 91 Fuel level sensor............................................................... 92 Engine coolant temperature sensor............................................... 93 Brake oil reservoir sensor...................................................... 94 Ribbon heater....................................................................... 95 Engine stop / start / preheating circuit............................................ 96 Electrical fuses and relays......................................................... 98 Fuses........................................................................... 98 Relays.......................................................................... 99 Engine room.....................................................................100 Electrical diagrams.................................................................101 Wiring diagram 1/5 - foldout 90-9...............................................101 Wiring diagram 2/5 - foldout 90-11..............................................101 Wiring diagram 3/5 - foldout 90-13..............................................101 Wiring diagram 4/5 - foldout 90-15..............................................101 Wiring diagram 5/5 - foldout 90-17..............................................101 Speed control - foldout 90-19...................................................101 Immobilizer - foldout 90-21.....................................................101 Air conditioner (option)............................................................102 Introduction....................................................................102 Function........................................................................103 The coolant circuit.........................................................103 The condenser...............................................................105 The vaporizer...............................................................106 The filter dryer............................................................107 Installation of air conditioner.................................................109 Safety when handling coolants...................................................110 Operating the air conditioner...................................................112 Maintenance of the air conditioner..............................................113 Regular maintenance.........................................................114 Instructions for filling........................................................116 Exchange of magnetic clutch.....................................................119 Exchange of compressor..........................................................120 Troubleshooting.................................................................122 TESTING AND ADJUSTING...................................................................127 Standard value table for engine - WA90-5 / WA100M-5.................................129 Standard value table for chassis - WA90-5...........................................130 Standard value table for chassis - WA100M-5.........................................132 Standard value table for electrical parts...........................................134 Test certificate - WA90-5...........................................................135 Test certificate - WA100M-5.........................................................136 Valve lash clearance................................................................137 Engine compression test.............................................................139 Injection nozzle pressure...........................................................140 Fuel injection timing...............................................................141 V-belt tension......................................................................143 Engine RPM..........................................................................144 RPM-dependant drive take-up.........................................................145 Engine stall torque RPM.............................................................146 Engine stall torque RPM, test with the hydrostatic drive........................146 Engine stall torque RPM, test with hydrostatic drive and working hydraulics.....147 Feed pump and servo oil pressure....................................................148 Hydraulic pressure cut-off..........................................................149 Working hydraulic pressure..........................................................151 Steering oil pressure...............................................................152 Testing.........................................................................152 Adjusting.......................................................................153 Pressure Accumulator................................................................154 Operating time for steering wheel...................................................155 Operating force of steering wheel...................................................155 Disc brake..........................................................................156 Inch valve - basic adjustment.......................................................157 Brake efficiency....................................................................158 Measuring the stopping distance.................................................158 Parking brake efficiency............................................................159 Travel speed........................................................................161 DISASSEMBLY AND ASSEMBLY................................................................163 Comments............................................................................165 Starter assembly....................................................................166 Removal of starter assembly.....................................................166 Installation of starter assembly................................................167 Alternator assembly.................................................................168 Removal of alternator assembly..................................................168 Installation of alternator assembly.............................................169 Water pump assembly.................................................................170 Removal of water pump assembly..................................................170 Installation of water pump assembly.............................................172 Engine cover assembly...............................................................173 Removal of engine cover assembly................................................173 Installation of engine cover assembly...........................................174 Engine cover support assembly.......................................................175 Removal of engine cover support assembly........................................175 Installation of engine cover support assembly...................................176 Engine assembly.....................................................................177 Removal of engine assembly......................................................177 Installation of engine assembly.................................................183 Clutch assembly.....................................................................185 Removal of clutch assembly......................................................185 Installation of clutch assembly.................................................186 Radiator assembly...................................................................187 Removal of radiator assembly....................................................187 Installation of radiator assembly...............................................189 Fan assembly........................................................................190 Removal of fan assembly.........................................................190 Installation of fan assembly....................................................191 Main brake cylinder assembly........................................................192 Removal of main brake cylinder assembly.........................................192 Installation of main brake cylinder assembly....................................193 Priority valve assembly.............................................................194 Removal of priority valve assembly..............................................194 Installation of priority valve assembly.........................................195 Orbit-roll-valve assembly...........................................................196 Removal of orbit-roll-valve assembly............................................196 Installation of orbit-roll-valve assembly.......................................198 Counterweight assembly..............................................................199 Removal of counterweight assembly...............................................199 Installation of counterweight assembly..........................................200 Main control valve assembly.........................................................201 Removal of main control valve assembly..........................................201 Installation of main control valve assembly.....................................202 Pilot valve assembly................................................................203 Removal of pilot valve assembly.................................................203 Installation of pilot valve assembly............................................204 Monitor assembly....................................................................205 Removal of monitor assembly.....................................................205 Installation of monitor assembly................................................206 Articulated joint assembly..........................................................207 Removal of articulated joint assembly...........................................207 Installation of articulated joint assembly......................................208 Variable motor assembly.............................................................209 Removal of variable motor assembly..............................................209 Installation of variable motor assembly.........................................211 Rear axle assembly..................................................................212 Removal of rear axle assembly...................................................212 Installation of rear axle assembly..............................................214 Front axle assembly.................................................................215 Removal of front axle assembly..................................................215 Installation of front axle assembly.............................................217 Front axle..........................................................................218 Brake disc group................................................................218 Disassembly.................................................................218 Assembly....................................................................220 Brake caliper.......................................................................222 Hydraulic principle of operation................................................222 Differential position...........................................................223 Mechanical principle of operation...............................................223 Caliper removal.................................................................223 Disassembly (calliper removed)..............................................224 Disassembly.................................................................224 Assembly....................................................................226 Caliper reassembly..............................................................228 Replacement of guide protective covers..........................................228 Pad replacement.................................................................229 Brake group - wheel shaft.......................................................230 Disassembly.................................................................230 Assembly....................................................................233 Rear axle...........................................................................236 Trunnions group and flange......................................................236 Disassembly.................................................................236 Assembly....................................................................237 Epicyclic reduction gear group..................................................239 Disassembly.................................................................239 Assembly....................................................................240 Wheel hub.......................................................................241 Disassembly.................................................................241 Assembly....................................................................243 Wheel shaft.....................................................................245 Disassembly.................................................................245 Assembly....................................................................246 Differential support group......................................................247 Disassembly.................................................................247 Assembly....................................................................248 Bevel gear marking test.........................................................252 Differential locking group......................................................253 Disassembly.................................................................253 Assembly....................................................................254 Differential group (100% Diff. Lock)............................................255 Disassembly.................................................................255 Assembly....................................................................256 Differential group (LSD 25%)....................................................257 Disassembly.................................................................257 Assembly....................................................................258 Pinion group....................................................................259 Disassembly.................................................................259 Assembly....................................................................260 Variable displacement pump assembly.................................................263 Removal of variable displacement pump assembly..................................263 Installation of variable displacement pump assembly.............................265 Hydraulic pump assemblies...........................................................266 Removal of the two hydraulic pump assemblies....................................266 Installation of hydraulic pump assembly.........................................267 Turbocharger assembly...............................................................268 Removal of the turbocharger.....................................................268 Installation of the turbocharger................................................268 Quick-attach coupler assembly.......................................................269 Removal of quick-attach coupler assembly........................................269 Installation of quick-attach coupler assembly...................................270 Steering cylinder assembly..........................................................271 Removal of steering cylinder assembly...........................................271 Installation of steering cylinder assembly......................................272 Lift cylinder assembly..............................................................273 Removal of lift cylinder assembly...............................................273 Installation of lift cylinder assembly..........................................274 Dump cylinder assembly..............................................................275 Removal of dump cylinder assembly...............................................275 Installation of dump cylinder assembly..........................................276 Replacing windows in driver’s cab...................................................277 Stuck glass.....................................................................277 Installation....................................................................279 Door and side windows...........................................................280 Door window assembly........................................................280 Side window assembly........................................................280 OTHERS..................................................................................281 Hydraulic circuit diagram 1/3...........................................................283 Hydraulic circuit diagram 2/3...........................................................285 Hydraulic circuit diagram 3/3...........................................................287 Wiring diagram 1/5......................................................................289 Wiring diagram 2/5......................................................................291 Wiring diagram 3/5......................................................................293 Wiring diagram 4/5......................................................................295 Wiring diagram 5/5......................................................................297 Wiring diagram, Speed control...........................................................299 Wiring diagram, Immobilizer.............................................................301
DESCRIPTION:
KOMATSU WA90-5 WA100M-5 WHEEL LOADER SHOP MANUAL VEBM270100 – PDF DOWNLOAD
General
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.
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.
This section gives the judgement standards when inspecting disassembled parts.
S.S 21/12/24
