Komatsu Wheel Loader WA80M-7 WA100M-7 service & repair manual

Description Komatsu Wheel Loader WA80M-7 WA100M-7 service & repair manual

Komatsu Wheel Loader WA80M-7, WA100M-7 pdf workshop service repair manual

Serial numbers:
H62051 and up

Technical data, specifications, maintenance, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Safety
Safety notice
Preparations for work
Tipping up the driver's cab
Tipping down the driver's cab
Precautions during work
Hydraulic system
Foreword
General
Structure and function
Testing and adjusting
Disassembly and assembly
Maintenance standard
How to read the shop manual
Volumes
Distribution and updating
Filing method
Symbols
Hoisting instructions
Wire ropes

General
Dimensions, weights and operating data
Specifications
Weight tables
Lubricants and operating mediums
Basic procedures of maintenance
Oil
Fuel
Coolant
Grease
Storing oil and fuel
Filters
Biodegradable hydraulic oils and lubricants
Outline of electric system
Torque list – Screws and nuts

Structure and Function
Powertrain
Closed circuit
Hydraulic drive system
WA80M-7 – Hydraulic drive system – 20 km/h and 30 km/h
WA100M-7 – Hydraulic drive system – 20 km/h and 30 km/h
Variable displacement pump (HST pump)
Regulating valve (DA valve)
WA80M-7 - Charge pump pressure relief valve - 20km/h
WA80M-7 , WA100M-7 - Charge pump pressure relief valve - 30km/h
Control cylinder
4/3 Way valve with direction control solenoids
Pressure cut-off valve
Safety & charge valve
Towing
Variable displacement motor (HST motor with HA Control)
Hydraulic diagram HST motor A6VM85 (or 150) HA1R1
Directional shuttle valve
Auto inch valve diagram (option)
HST motor with DA Control
Hydraulic diagram HST Motor A6VM107(160)DA2
Drive shaft
Front axle – Mounting
WA80M-7, WA100M-7 – Front axle mounting
Rear axle – Mounting
Front axle
WA80M-7 – Front axle with inner disc brake as service brake and outer disc brake as parking brake
WA100M-7 – Front axle with inner disc brake as service brake and outer disc brake as parking brake
Rear axle with transfer box
WA80M-7 – Rear axle with transfer box
WA100M-7 – Rear axle with transfer box
Transfer box TB172
Limited slip differential
Limited slip differential – Locking value 25%
Locking differential
Locking differential – Locking value 100%
Wheel hub – Font axle and rear axle
Service and parking brake – Front axle
WA80M-7, WA100M-7 – Service brake
WA80M-7, WA100M-7 – Parking brake
Service and parking brake circuit
WA80M-7 – Service and parking brake circuit
WA100M-7 – Service and parking brake circuit
Service brake assembly
WA80M-7, WA100M-7 – Service brake assembly
Main-brake valve
WA80M-7, WA100M-7 – Main-brake valve
Steering articulation joint
Steering system
WA80M-7 – Hydraulic circuit diagram of steering system
WA100M-7 – Hydraulic circuit diagram of steering system
Priority valve
Orbit-roll-valve
Steering relief valve
Work equipment hydraulic
WA80M-7 – Travel, steering and work hydraulics
WA100M-7 – Travel, steering and work hydraulics
PPC-Valve WA100M-7
Operation of PPC-valve
Servo pressure regulating valve
Emergency Lowering System
Main control valve
Main control valve WA80M-7
Main control valve WA100M-7
Lift cylinder
WA80M-7 – Lift cylinder
WA100M-7 – Lift cylinder
Dump cylinder
WA80M-7 – Dump cylinder
WA100M-7 – Dump cylinder
Steering cylinder
WA80M-7 – Steering cylinder
WA100M-7 – Steering cylinder
Loader Linkage with quick-coupler
WA80M-7, WA100M-7 – Loader Linkage with quick-coupler
Quick-coupler
WA80M-7 – Quick-coupler
WA100M-7 – Quick-coupler
Monitor display
WA80M-7, WA100M-7 – Monitor display
Special monitor functions
Monitor Service Menu
Reading Fault codes
Fault Codes List
Sensors
Engine oil pressure switch
Fuel level sensor
Engine coolant temperature sensor
Brake oil reservoir sensor
Ambient pressure sensor
Charge (boost) pressure and temperature sensor
NE (crankshaft) speed sensor
Bkup (camshaft) speed sensor
Common rail pressure sensor
Crankcase pressure sensor
Mass air flow and temperature sensor
Variable Flow Turbocharger motor (with built-in position sensor)
EGR valve (with built-in position sensor)
Pre-heater
WA80M-7, WA100M-7 – Ribbon heater
Electrical fuses and relays
Fuses
Slow-blow fuses
Relays
Diagrams
Wiring diagrams
Hydraulic circuit diagram
Air conditioner (option)
Introduction
Function
The coolant circuit
The condenser
The vaporizer
The filter dryer
Installation of air conditioner
Safety when handling coolants
Operating the air conditioner
Maintenance of the air conditioner
Regular maintenance
Instructions for filling
Exchange of magnetic clutch
Exchange of compressor
Troubleshooting

Testing and Adjusting
Standard value table for engine
WA80M-7 - Standard value table for engine
WA100M-7 - Standard value table for engine
Standard value table for chassis
WA80M-7 - Standard value table for chassis
WA100M-7 - Standard value table for chassis
Standard value table for electrical parts
Test certificate
WA80M-7 - Test certificate
WA100M-7 - Test certificate
Valve clearance
WA80M-7, WA100M-7 - Valve clearance
Engine compression test
WA80M-7, WA100M-7 - Engine compression test
Fuel system
WA80M-7, WA100M-7 - Testing fuel pressure
WA80M-7, WA100M- 7 Testing leakage from pressure limiter and return rate from injector
WA80M-7, WA100M-7 - Bleeding air from fuel circuit
WA80M-7, WA100M-7 - Testing fuel system for leakage
V-belt tension
Engine RPM
Testing travel speed
Engine stall torque RPM
Engine stall torque RPM, test with the hydrostatic drive
Engine stall torque RPM, test with hydrostatic drive and working hydraulics
Feed pump (and servo oil pressure) 
Hydraulic pressure cut-off
Working hydraulic pressure
Steering oil pressure
Testing
Adjusting
Operating time for steering wheel
Operating force of steering wheel
Disc brake (foot brake)
WA80M-7, WA100M-7 - Disc brake (foot brake)
Main brake valve – basic adjustment
Brake efficiency
Measuring the stopping distance
Parking brake efficiency
Ventilation / filling up the brake circuit
WA80M-7, WA100M-7 - Ventilation / filling up the brake circuit
Cabin - adjustment
Proportional amplifier
WA100M-7 Test certificate

Disassembly and Assembly
Starter assembly
Removal of starter assembly
Installation of starter assembly
Alternator assembly
Removal of alternator assembly
Installation of alternator assembly
Counterweight assembly
Removal of counterweight assembly
Installation of counterweight assembly
Engine cover assembly
Removal of engine cover assembly
Installation of engine cover assembly
Radiator and hydraulic tank assembly
Removal of radiator and hydraulic tank assembly
Installation of radiator and hydraulic tank assembly
Fan assembly
Removal of fan assembly
Installation of fan assembly
Water pump assembly
Removal of water pump assembly
Installation of water pump assembly
Engine assembly
Removal of engine assembly
Installation of engine assembly
Clutch assembly
Removal of clutch assembly
Installation of clutch assembly
Fuel tank assembly
Removal and installation of fuel tank assembly
Installation
Main brake valve assembly
Removal of main brake valve assembly
Installation of main brake valve assembly
Priority valve assembly
Removal of priority valve assembly
Installation of priority valve assembly
Orbit-roll-valve assembly
Removal of orbit-roll-valve assembly
Installation of orbit-roll-valve assembly
Main control valve assembly WA80M-7
Removal of pilot valve assembly
Installation of main control valve assembly
Main control valve assembly - WA100M-7
Removal of main control valve assembly
Installation of main control valve assembly
Pilot valve assembly WA100M-7
Removal of pilot valve assembly
Installation of pilot valve assembly
Monitor assembly
Removal of monitor assembly
Installation of monitor assembly
Articulated joint assembly
Removal of articulated joint assembly
Installation of articulated joint assembly
Variable motor assembly
Removal of variable motor assembly
Installation of variable motor assembly
Rear axle assembly
Removal of rear axle assembly
Installation of rear axle assembly
Front axle assembly
Removal of front axle assembly
Installation of front axle assembly
Front axle
Brake disc group
Disassembly
Assembly
Brake calliper
Hydraulic principle of operation
Differential position
Mechanical principle of operation
Calliper removal
Disassembly (calliper removed)
Disassembly
Assembly
Calliper reassembly
Replacement of guide protective covers
Pad replacement
Brake group - wheel shaft
Disassembly
Assembly
Rear axle
Trunnions group and flange
Disassembly
Assembly
Epicyclic reduction gear group
Disassembly
Assembly
Wheel hub
Disassembly
Assembly
Wheel shaft - WA80M-7, WA100M-7
Disassembly
Assembly
Differential support group
Disassembly
Assembly
Bevel gear marking test
Differential locking group
Disassembly
Assembly
Differential group (100% Differential Lock)
Disassembly
Assembly
Differential group (LSD 25%)
Disassembly
Assembly
Pinion group
Disassembly
Assembly
Transmission box
Disassembly
Assembly
Variable displacement pump assembly
Removal of variable displacement pump assembly
Installation of variable displacement pump assembly
Hydraulic pump assemblies
Removal of the two hydraulic pump assemblies
Installation of hydraulic pump assembly 
Variable geometry turbocharger assembly - WA80M-7, WA100M-7
Removal of the turbocharger
Installation of the turbocharger
Quick coupler assembly
Removal of quick coupler assembly
Installation of quick coupler assembly
Steering cylinder assembly
Removal of steering cylinder assembly
Installation of steering cylinder assembly
Lift cylinder assembly
Removal of lift cylinder assembly
Installation of lift cylinder assembly
Dump cylinder assembly
Removal of dump cylinder assembly
Installation of dump cylinder assembly
Replacing windows in driver’s cab
Stuck glass
Installation
Door and side windows
Door window assembly
Side window assembly

Hydraulic circuit diagram
Wiring diagram

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