Komatsu WA65-5, WA70-5, WA80-5 H50051 & Up VEBM250100 (Preview)
VEBM250100_WA65-5_WA80-5_Shop_Manual
SAFETY
Safety notice
Preparations for work
Tipping up the driver’s cab
Tipping down the driver’s cab
Precautions during work
Foreword
How to read the shop manual
Volumes
Distribution and updating
Filing method
Symbols
Hoisting instructions
Wire ropes
GENERAL
Dimensions, weights and operating data WA65-5
Specifications WA65-5
Weight table WA65-5
Dimensions, weights and operating data WA70-5
Specifications WA70-5
Weight table WA70-5
Dimensions, weights and operating data WA80-5
Specifications WA80-5
Weight table WA80-5
Lubricants and operating mediums: WA65-5/ WA70-5
Lubricants and operating mediums: WA80-5
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 20Km/h
Hydraulic drive system 30Km/h
Variable displacement pump
Regulating valve
Charge pressure limiting valve
Control cylinder
4/3 Way valve with direction control solenoids
Pressure cut-off valve
Safety-/charge valve
Towing
Variable displacement motor
Drive shaft
Axle mounting – front axle
Axle mounting – rear axle
WA65-5 / WA70-5: Front axle
With outer disc brake as service brake and parking brake
WA80-5: Front axle
With inner disc brake as service brake and outer disc brake as parking brake
Rear axle with transfer box
Transfer box TB172
Limited slip differential (locking value 25%)
Locking differential (locking value 100%)
Wheel hub, front and rear axle
WA65-5 / WA70-5: Service and parking brake, front axle
WA80-5: Service brake, front axle
WA80-5: Parking brake, front axle
Sevice and parking brake circuit
WA65-5 / WA70-5: Service brake assembly
WA80-5: Service brake assembly
Inch-brake Valve
Steering articulation joint
Steering system
Hydraulic circuit diagram of steering system
Priority valve
Orbit-roll-valve
Steering relief valve
Work equipment hydraulic WA65/WA70-5
Travel, steering and work hydraulics
Work equipment hydraulic WA80-5
Travel, steering and work hydraulics
PPC-Valve
Operation of PPC-valve
Servo pressure regulating valve
Emergency Lowering System
Main control valve
WA65-5 / WA70-5: Lift cylinder
WA80-5: Lift cylinder
Dump cylinder
Steering cylinder
Lifting frame with quick-coupler
Quick-coupler
Monitor display
Sensors
Engine oil pressure sensor
Fuel level sensor
Engine coolant temperature sensor
Brake oil reservoir sensor
Ribbon heater
Engine stop / start / preheating circuit
Electrical fuses and relays
Fuses
Relays
Engine room
Electrical diagrams
Wiring diagram 1/5 – foldout 90-9
Wiring diagram 2/5 – foldout 90-11
Wiring diagram 3/5 – foldout 90-13
Wiring diagram 4/5 – foldout 90-15
Wiring diagram 5/5 – foldout 90-17
Speed control – foldout 90-19
Immobilizer – foldout 90-21
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 – WA65-5 / WA70-5 / WA80-5
Standard value table for chassis – WA65-5
Standard value table for chassis – WA70-5
Standard value table for chassis – WA80-5
Standard value table for electrical parts
Test certificate – WA65-5
Test certificate – WA70-5
Test certificate – WA80-5
Valve lash clearance
Engine compression test
Injection nozzle pressure
Fuel injection timing
V-belt tension
Engine RPM
RPM-dependant drive take-up
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 for WA80-5)
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 WA80-5)
Brake (WA65-5 and WA70-5)
Inch valve – basic adjustment
WA 65-5 and WA70-5
WA 80-5
Brake efficiency
Measuring the stopping distance
Parking brake efficiency
Travel speed
DISASSEMBLY AND ASSEMBLY
Comments
Starter assembly
Removal of starter assembly
Installation of starter assembly
Alternator assembly
Removal of alternator assembly
Installation of alternator assembly
Water pump assembly
Removal of water pump assembly
Installation of water pump assembly
Engine cover assembly
Removal of engine cover assembly
Installation of engine cover assembly
Engine cover support assembly
Removal of engine cover support assembly
Installation of engine cover support assembly
Engine assembly
Removal of engine assembly
Installation of engine assembly
Clutch assembly
Removal of clutch assembly
Installation of clutch assembly
Radiator assembly
Removal of radiator assembly
Installation of radiator assembly
Fan assembly
Removal of fan assembly
Installation of fan assembly
Inch brake valve assembly
Removal of inch brake valve assembly
Installation of inch 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
Counterweight assembly
Removal of counterweight assembly
Installation of counterweight assembly
Control valve assembly (WA65-5 / WA70-5)
Removal of control valve assembly
Installation of control valve assembly
Main control valve assembly (WA80-5)
Removal of main control valve assembly
Installation of main control valve assembly
Pilot valve assembly (WA80-5)
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 caliper
Hydraulic principle of operation
Differential position
Mechanical principle of operation
Caliper removal
Disassembly (calliper removed)
Disassembly
Assembly
Caliper 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
Disassembly
Assembly
Differential support group
Disassembly
Assembly
Bevel gear marking test
Differential locking group
Disassembly
Assembly
Differential group (WA80-5)
Disassembly
Assembly
Differential group (WA65-5 / WA70-5)
Disassembly
Assembly
Pinion group
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
Quick-attach coupler assembly
Removal of quick-attach coupler assembly
Installation of quick-attach 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
OTHERS
Wiring diagram1/5
Wiring diagram 2/5
Wiring diagram 3/5
Wiring diagram 4/5
Wiring diagram 5/5
Wiring diagram, Speed control
Wiring diagram, Immobilizer
Hydraulic circuit diagram 1/4
Hydraulic circuit diagram 2/4
Hydraulic circuit diagram 3/4
Hydraulic circuit diagram 4/4
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