FIRSTDRAFT
WHEELLOADER
•Thisshopmanualmaycontainattachmentsandoptionalequipmentthatarenotavailableinyourarea. PleaseconsultyourlocalKOMATSUdistributorforthoseitemsyoumayrequire.
•Materialsandspecificationsaresubjecttochangewithoutnotice.
•TheWheelLoaderWA80M-7isequippedwiththeengineSAA4D95LE-6. TheWheelLoaderWA100M-7isequippedwiththeengineSAA4D95LE-6.
•FordetailsofthisengineseeEngineManual:WA80M-7,WA100M-7inattachment
StructureandFunction Powertrain............................................................................10-5
WA80M-7–Hydraulicdrivesystem–20km/hand30km/h...................................10-7
WA100M-7–Hydraulicdrivesystem–20km/hand30km/h..................................10-8
Variabledisplacementpump(HSTpump)..................................................10-9
Regulatingvalve(DAvalve)..........................................................10-12
WA80M-7-Chargepumppressurereliefvalve-20km/h....................................10-13
WA80M-7,WA100M-7-Chargepumppressurereliefvalve-30km/h..........................10-13
Controlcylinder....................................................................10-14
4/3Wayvalvewithdirectioncontrolsolenoids............................................10-15
Variabledisplacementmotor(HSTmotorwithHAControl)..................................10-19
WA80M-7,WA100M-7–Frontaxlemounting.............................................10-26 Rearaxle–Mounting..................................................................10-27
WA80M-7–Frontaxlewithinnerdiscbrakeasservicebrakeandouterdiscbrakeasparkingbrake..10-28
WA100M-7–Frontaxlewithinnerdiscbrakeasservicebrakeandouterdiscbrakeasparkingbrake.10-29
WA80M-7–Rearaxlewithtransferbox.................................................10-30
WA100M-7–Rearaxlewithtransferbox................................................10-31
WA80M-7,WA100M-7–Servicebrake..................................................10-40
WA80M-7,WA100M-7–Parkingbrake..................................................10-41
ReadingFaultcodes................................................................10-87
FaultCodesList....................................................................10-88
Sensors.............................................................................10-90
Engineoilpressureswitch............................................................10-91
Fuellevelsensor...................................................................10-92
Enginecoolanttemperaturesensor.....................................................10-93
Brakeoilreservoirsensor............................................................10-94
Ambientpressuresensor.............................................................10-94
Charge(boost)pressureandtemperaturesensor..........................................10-95
NE(crankshaft)speedsensor.........................................................10-95
Bkup(camshaft)speedsensor........................................................10-96
Commonrailpressuresensor.........................................................10-96
Crankcasepressuresensor...........................................................10-97
Massairflowandtemperaturesensor...................................................10-97
VariableFlowTurbochargermotor(withbuilt-inpositionsensor)..............................10-98
EGRvalve(withbuilt-inpositionsensor).................................................10-99
Pre-heater
Standardvaluetableforchassis..........................................................20-6
WA80M-7-Standardvaluetableforchassis...............................................20-6
WA100M-7-Standardvaluetableforchassis..............................................20-8
Standardvaluetableforelectricalparts...................................................20-10
Testcertificate........................................................................20-11
WA80M-7-Testcertificate............................................................20-11
WA100M-7-Testcertificate...........................................................20-12
Valveclearance.......................................................................20-13
WA80M-7,WA100M-7-Valveclearance.................................................20-13
Enginecompressiontest...............................................................20-15
WA80M-7,WA100M-7-Enginecompressiontest..........................................20-15
Fuelsystem..........................................................................20-18
WA80M-7,WA100M-7-Testingfuelpressure.............................................20-20
WA80M-7,WA100M-7Testingleakagefrompressurelimiterandreturnratefrominjector..........20-23
WA80M-7,WA100M-7-Bleedingairfromfuelcircuit.......................................20-26
WA80M-7,WA100M-7-Testingfuelsystemforleakage.....................................20-28
Diagrams
Wiringdiagram4/8–WA80M-7,WA100M-7
Wiringdiagram6/8–WA80M-7,WA100M-7
Wiringdiagram7/8–WA80M-7,WA100M-7................................................90-11
Wiringdiagram8/8–WA80M-7,WA100M-7................................................90-12
EngineManual:WA80M-7,WA100M-7
Safetynotice
ImportantSafetyNotice
Properserviceandrepairisextremelyimportantforsafe machineoperation.Someofthedescribedserviceandrepairtechniquesrequiretheuseoftoolsspeciallydesigned byKomatsuforthespecificpurpose.
Topreventinjurytoworkers,thesymbolisusedtomark safetyprecautionsinthismanual.Thecautionsaccompanyingthesesymbolsmustalwaysbefollowedcarefully.If anydangeroussituationarisesormaypossiblyarise,first considersafety,andtakethenecessaryactionstodealwith thesituation.
GeneralPrecautions
Mistakesinoperationareextremelydangerous.Readthe OPERATIONANDMAINTENANCEMANUALcarefullybefore operatingthemachine!Alwaysfollowthesafetyrulesvalid inyourcountrycarefully!
1.Beforecarryingoutanygreasingorrepairs,readalltheprecautionsgivenonthedecalswhicharefixedtothemachine.
2.Whencarryingoutanyoperation,alwayswearsafetyshoes andhelmet.Donotwearlooseworkclothes,orclotheswith buttonsmissing.
•Alwayswearsafetyglasseswhenhittingpartswitha hammer.
•Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained,experiencedweldercarryoutthework.Whencarryingoutwelding work,alwayswearweldinggloves,apron,glasses,capand otherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormoreworkers, alwaysagreeontheoperatingprocedurebeforestarting.Alwaysinformyourfellowworkersbeforestartinganystepof theoperation.Beforestartingwork,hangUNDERREPAIR signsonthecontrolsintheoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrectwayto usethem.
6.Decideaplaceintherepairworkshoptokeeptoolsandremovedparts.Alwayskeepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareacleanandmakesure thatthereisnodirtoroilonthefloor.Neversmokewhile working.Smokeonlyintheareasprovidedforsmoking.
Preparationsforwork
1.Beforeaddingoilormakinganyrepairs,parkthemachine onhard,levelground,andblockthewheelsortrackstopreventthemachinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketoranyother workequipmenttothegroundandinstallthesafetybaron theframe.Ifthisisnotpossible,insertthesafetypinoruse blockstopreventtheworkequipmentfromfalling.Inaddition,besuretolockallthecontrolleversandhangwarning signsonthem.
3.Whendisassemblingorassembling,supportthemachine withblocks,jacksorstandsbeforestartingwork.
4.Removeallmudandoilfromthestepsorotherplacesused togetonandoffthemachine.Alwaysusethehandrails,laddersorstepswhengettingonoroffthemachine.Never jumponoroffthemachine.Ifitisimpossibletousethe handrails,laddersorsteps,useastandtoprovidesafefooting.